PK3 Mech Specs

P1268 Camp Geiger GWOT SOI
123044
SECTION 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS 08/10 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA) AMCA 201 AMCA 210 (2002) Fans and Systems (2007) Laboratory Methods of Testing Fans for Aerodynamic Performance Rating (2008) Reverberant Room Method for Sound Testing of Fans (2006; INT 2007; Errata 2008) Methods for Calculating Fan Sound Ratings from Laboratory Test Data AIR-CONDITIONING, HEATING AND REFRIGERATION INSTITUTE (AHRI) AHRI 260 (2001) Sound Rating of Ducted Air Moving and Conditioning Equipment (2008) Sound Rating of Non-Ducted Indoor Air-Conditioning Equipment (2001; Addendum 1-2002; Addendum 2-2005) Forced-Circulation Air-Cooling and Air-Heating Coils (2009) Central-Station Air-Handling Units (2008) Room Fan-Coils and Unit Ventilators (2008) Performance Rating of Air Terminals (2008) Procedure for Estimating Occupied Space Sound Levels in the Application of Air Terminals and Air Outlets (1996) Application and Installation of Central Station Air-Handling Units
AMCA 300
AMCA 301
AHRI 350
AHRI 410
AHRI 430 AHRI 440 AHRI 880 AHRI 885
AHRI Guideline D
AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA) ABMA 11 (1990) Load Ratings and Fatigue Life for Roller Bearings
SECTION 23 00 00
Page 1
123044
ABMA 9
(1990; R 2008) Load Ratings and Fatigue Life for Ball Bearings AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)
ASHRAE 52.2
(2007; Addenda B 2008; Errata 2009, Errata 2010; INT 2010) Method of Testing General Ventilation Air-Cleaning Devices for Removal Efficiency by Particle Size (2010; Errata 2010; Errata Ventilation for Acceptable Quality(2010; Errata 2010; Ventilation for Acceptable Quality 2011) Indoor Air Errata 2011) Indoor Air
ASHRAE 62.1
ASHRAE 68
(1997) Laboratory Method of Testing to Determine the Sound Power In a Duct (2006; r 2011) Method of Testing for Rating the Performance of Air Outlets and Inlets
ASHRAE 70
ASME INTERNATIONAL (ASME) ASME A13.1 (2007) Scheme for the Identification of Piping Systems
ASTM INTERNATIONAL (ASTM) ASTM A123/A123M (2009) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products (1999; R 2009) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip (2010) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless (2010a) Standard Specification for General Requirements for Steel Sheet, Metallic-Coated by the Hot-Dip Process (2009) Standing Practice for Operating Salt Spray (Fog) Apparatus (1986; R 2008) Standard Specification for Electrodeposited Coatings of Cadmium (2005e1) Standard Specification for Fibrous Glass Duct Lining Insulation (Thermal and Sound Absorbing Material) (2008) Standard Specification for Mineral SECTION 23 00 00 Page 2
ASTM A167
ASTM A53/A53M
ASTM A924/A924M
ASTM B 117
ASTM B 766
ASTM C 1071
ASTM C 553
123044
Fiber Blanket Thermal Insulation for Commercial and Industrial Applications ASTM D 1654 (2008) Evaluation of Painted or Coated Specimens Subjected to Corrosive Environments (2009e2) Measuring Adhesion by Tape Test (2000; R 200511) Zinc Dust Pigment (2006) Standard Specification for Industrial Woven Wire Cloth (1987; R 2007) Standard Specification for Filter Units, Air Conditioning, Viscous Impingement and Dry Types, Replaceable
ASTM D 3359 ASTM D 520 ASTM E 2016
ASTM F 1040
INTERNATIONAL CODE COUNCIL (ICC) ICC IBC (2009; Errata First Printing) International Building Code NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA ICS 6 NEMA MG 1 NEMA MG 10 (1993; R 2006) Enclosures (2009) Motors and Generators (2001; R 2007) Energy Management Guide for Selection and Use of Fixed Frequency Medium AC Squirrel-Cage Polyphase Induction Motors (1977; R 2007) Energy Management Guide for Selection and Use of Single Phase Motors
NEMA MG 11
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA 70 (2011) National Electrical Code(2008) National Electrical Code (2010) Standard Methods of Fire Tests for Flame Propagation of Textiles and Films (2009; Errata 09-1) Standard for the Installation of Air Conditioning and Ventilating Systems SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA) SMACNA 1819 (2002) Fire, Smoke and Radiation Damper Installation Guide for HVAC Systems, 5th Edition (2003) Fibrous Glass Duct Construction Standards, 7th Edition
NFPA 701
NFPA 90A
SMACNA 1884
SECTION 23 00 00
Page 3
123044
SMACNA 1966
(2005) HVAC Duct Construction Standards Metal and Flexible, 3rd Edition
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA) 40 CFR 82 Protection of Stratospheric Ozone
UNDERWRITERS LABORATORIES (UL) UL 181 (2005; Reprint Oct 2008) Factory-Made Air Ducts and Air Connectors (2005; Reprint Jul 2009) Heating and Cooling Equipment (2006; Reprint May 2010) Standard for Fire Dampers (2009) Standard for High-Efficiency Particulate, Air Filter Units (2007; reprint Nov 2010) Electrical Rigid Metal Conduit-Steel (2004; Reprint Oct 2009) Standard for Power Ventilators (2004; Reprint Nov 2009) Standard for Air Filter Units (2011) Building Materials Directory (2009) Electrical Construction Equipment Directory (2011) Fire Resistance Directory
UL 1995
UL 555
UL 586
UL 6
UL 705
UL 900
UL Bld Mat Dir UL Electrical Constructn
UL Fire Resistance 1.2 SYSTEM DESCRIPTION
Furnish ductwork, piping offsets, fittings, and accessories as required to provide a complete installation. Coordinate the work of the different trades to avoid interference between piping, equipment, structural, and electrical work. Provide complete, in place, all necessary offsets in piping and ductwork, and all fittings, and other components, required to install the work as indicated and specified. 1.2.1 Mechanical Equipment Identification
The number of charts and diagrams shall be equal to or greater than the number of mechanical equipment rooms. Where more than one chart or diagram per space is required, mount these in edge pivoted, swinging leaf, extruded aluminum frame holders which open to 170 degrees. 1.2.1.1 Charts
Provide chart listing of equipment by designation numbers and capacities such as flow rates, pressure and temperature differences, heating and cooling capacities, horsepower, pipe sizes, and voltage and current characteristics. SECTION 23 00 00 Page 4
123044
[1.2.1.2
Diagrams
Submit proposed diagrams, at least 2 weeks prior to start of related testing. provide neat mechanical drawings provided with extruded aluminum frame under 1/8-inch glass or laminated plastic, system diagrams that show the layout of equipment, piping, and ductwork, and typed condensed operation manuals explaining preventative maintenance procedures, methods of checking the system for normal, safe operation, and procedures for safely starting and stopping the system. After approval, post these items where directed. ]1.2.2 Service Labeling
Label equipment, including fans, air handlers, terminal units, etc. with labels made of self-sticking, plastic film designed for permanent installation. Labels shall be in accordance with the typical examples below: SERVICE Air handling unit Number Control and instrument air Exhaust Fan Number VAV Box Number LABEL AND TAG DESIGNATION AHU - 01, 02, etc.[_____] CONTROL AND INSTR. EF 01, 02, etc.[_____]
VAV - ### (where ### is the room number)[_____] FC TB UV [_____] [_____] [_____]
Fan Coil Unit Number Terminal Box Number Unit Ventilator Number
Identify similar services with different temperatures or pressures. Where pressures could exceed 125 pounds per square inch, gage, include the maximum system pressure in the label. Label and arrow piping in accordance with the following: a. b. c. Each point of entry and exit of pipe passing through walls. Each change in direction, i.e., elbows, tees. In congested or hidden areas and at all access panels at each point required to clarify service or indicated hazard. In long straight runs, locate labels at distances within eyesight of each other not to exceed 75 feet. All labels shall be visible and legible from the primary service and operating area. For Bare or Insulated Pipes for Outside Diameters of 1/2 thru 1-3/8 inch 1-1/2 thru 2-3/8 inch 2-1/2 inch and larger
d.
Lettering 1/2 inch 3/4 inch 1-1/4 inch
SECTION 23 00 00
Page 5
123044
1.2.3
Color Coding
Color coding of all piping systems shall be in accordance with [ASME A13.1] [MIL-STD-101]. 1.3 SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for [Contractor Quality Control approval.] [information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] Submit the following in accordance with Section 01 33 00.05 20 CONSTRUCTION SUBMITTAL PROCEDURES: [SD-02 Shop Drawings] [Detail Drawings[; G][; G, [_____]]] SD-03 Product Data Metallic Flexible Duct Insulated Nonmetallic Flexible Duct Runouts Duct Connectors Duct Access Doors[; G][; G, [_____]] Fire Dampers Manual Balancing Dampers[; G][; G, [_____]] Automatic Smoke-Fire Dampers Automatic Smoke Dampers Sound Attenuation Equipment Acoustical Duct Liner Diffusers Registers and Grilles Louvers Air Vents, Penthouses, and Goosenecks Centrifugal Fans In-Line Centrifugal Fans Axial Flow Fans Panel Type Power Wall Ventilators Centrifugal Type Power Wall Ventilators Centrifugal Type Power Roof Ventilators Propeller Type Power Roof Ventilators Air-Curtain Fans Ceiling Exhaust Fans Air Handling Units[; G][; G, [_____]] Room Fan-Coil Units[; G ][; G, [_____]] Coil Induction Units[; G][; G, [_____]] Constant Volume, Single Duct Terminal Units[; G][; G, [_____]] Variable Volume, Single Duct Terminal Units[; G][; G, [_____]] Variable Volume, Single Duct, Fan-Powered Terminal Units[; G][; G, [_____]] Dual Duct Terminal Units[; G][; G, [_____]] Ceiling Induction Terminal Units[; G][; G, [_____]] Reheat Units[; G][; G, [_____]] Unit Ventilators Energy Recovery Devices[; G][; G, [_____]] [Test Procedures] Diagrams[; G][; G, [_____]] SECTION 23 00 00 Page 6
123044
SD-06 Test Reports Performance Tests[; G][; G, [_____]] Damper Acceptance Test[; G][; G, [_____]] [SD-07 Certificates] [Bolts] SD-08 Manufacturer's Instructions Manufacturer's Installation Instructions Operation and Maintenance Training SD-10 Operation and Maintenance Data Operation and Maintenance Manuals Fire Dampers[; G][; G, [_____]] Manual Balancing Dampers[; G][; G, [_____]] Automatic Smoke-Fire Dampers[; G][; G, [_____]] Automatic Smoke Dampers[; G][; G, [_____]] Centrifugal Fans[; G Panel Type Power Wall Ventilators][; G, [_____]] In-Line Centrifugal Fans[; G][; G, [_____]] Axial Flow Fans[; G][; G, [_____]] Panel Type Power Wall Ventilators[; G][; G, [_____]] Centrifugal Type Power Wall Ventilators[; G][; G, [_____]] Centrifugal Type Power Roof Ventilators[; G][; G, [_____]] Propeller Type Power Roof Ventilators[; G][; G, [_____]] Air-Curtain Fans[; G][; G, [_____]] Ceiling Exhaust Fans[; G][; G, [_____]] Air Handling Units[; G][; G, [_____]] Room Fan-Coil Units[; G ][; G, [_____]] Coil Induction Units[; G][; G, [_____]] Constant Volume, Single Duct Terminal Units[; G][; G, [_____]] Variable Volume, Single Duct Terminal Units[; G][; G, [_____]] Variable Volume, Single Duct, Fan-Powered Terminal Units[; G][; G, [_____]] Dual Duct Terminal Units[; G][; G, [_____]] Ceiling Induction Terminal Units[; G][; G, [_____]] Reheat Units[; G][; G, [_____]] Unit Ventilators[; G][; G, [_____]] Energy Recovery Devices[; G][; G, [_____]] 1.4 QUALITY ASSURANCE
Except as otherwise specified, approval of materials and equipment is based on manufacturer's published data. a. Where materials and equipment are specified to conform to the standards of the Underwriters Laboratories, the label of or listing with reexamination in UL Bld Mat Dir, and UL 6 is acceptable as sufficient evidence that the items conform to Underwriters Laboratories requirements. In lieu of such label or listing, submit a written certificate from any nationally recognized testing agency, adequately equipped and competent to perform such services, stating that the items SECTION 23 00 00 Page 7
123044
have been tested and that the units conform to the specified requirements. Outline methods of testing used by the specified agencies. b. Where materials or equipment are specified to be constructed or tested, or both, in accordance with the standards of the ASTM International (ASTM), the ASME International (ASME), or other standards, a manufacturer's certificate of compliance of each item is acceptable as proof of compliance. Conformance to such agency requirements does not relieve the item from compliance with other requirements of these specifications. Prevention of Corrosion
c.
1.4.1
Protect metallic materials against corrosion. Manufacturer shall provide rust-inhibiting treatment and standard finish for the equipment enclosures. Do not use aluminum in contact with earth, and where connected to dissimilar metal. Protect aluminum by approved fittings, barrier material, or treatment. Ferrous parts such as anchors, bolts, braces, boxes, bodies, clamps, fittings, guards, nuts, pins, rods, shims, thimbles, washers, and miscellaneous parts not of corrosion-resistant steel or nonferrous materials shall be hot-dip galvanized in accordance with ASTM A123/A123M for exterior locations and cadmium-plated in conformance with ASTM B 766 for interior locations.[ Provide written certification from the bolt manufacturer that the bolts furnished comply with the requirements of this specification. Include illustrations of product markings, and the number of each type of bolt to be furnished in the certification.] 1.4.2 Asbestos Prohibition
Do not use asbestos and asbestos-containing products. 1.4.3 Ozone Depleting Substances Used as Refrigerants
Minimize releases of Ozone Depleting Substances (ODS) during repair, maintenance, servicing or disposal of appliances containing ODS's by complying with all applicable sections of 40 CFR 82 Part 82 Subpart F. Any person conducting repair, maintenance, servicing or disposal of appliances owned by NASA shall comply with the following: a. Do not knowingly vent or otherwise release into the environment, Class I or Class II substances used as a refrigerant. Do not open appliances without meeting the requirements of 40 CFR 82 Part 82.156 Subpart F, regarding required practices for evacuation and collection of refrigerant, and 40 CFR 82 Part 82.158 Subpart F, regarding standards of recycling and recovery equipment. Only persons who comply with 40 CFR 82 Part 82.161 Subpart F, regarding technician certification, can conduct work on appliances containing refrigerant.
b.
c.
In addition, provide copies of all applicable certifications to the Contracting Officer at least 14 calendar days prior to initiating maintenance, repair, servicing, dismantling or disposal of appliances, including:
SECTION 23 00 00
Page 8
123044
a. b. c. 1.4.4
Proof of Technician Certification Proof of Equipment Certification for recovery or recycling equipment. Proof of availability of certified recovery or recycling equipment. Use of Ozone Depleting Substances, Other than Refrigerants
The use of Class I or Class II ODS's listed as nonessential in 40 CFR 82 Part 82.66 Subpart C is prohibited. These prohibited materials and uses include: a. Any plastic party spray streamer or noise horn which is propelled by a chlorofluorocarbon Any cleaning fluid for electronic and photographic equipment which contains a chlorofluorocarbon; including liquid packaging, solvent wipes, solvent sprays, and gas sprays. Any plastic flexible or packaging foam product which is manufactured with or contains a chlorofluorocarbon, including, open cell foam, open cell rigid polyurethane poured foam, closed cell extruded polystyrene sheet foam, closed cell polyethylene foam and closed cell polypropylene foam except for flexible or packaging foam used in coaxial cabling. Any aerosol product or other pressurized dispenser which contains a chlorofluorocarbon, except for those listed in 40 CFR 82 Part 82.66 Subpart C.
b.
c.
d.
Request a waiver if a facility requirement dictates that a prohibited material is necessary to achieve project goals. Submit the waiver request in writing to the Contracting Officer. The waiver will be evaluated and dispositioned. 1.4.5 Detail Drawings
Submit detail drawings showing equipment layout, including assembly and installation details and electrical connection diagrams; ductwork layout showing the location of all supports and hangers, typical hanger details, gauge reinforcement, reinforcement spacing rigidity classification, and static pressure and seal classifications. Include any information required to demonstrate that the system has been coordinated and functions properly as a unit on the drawings and show equipment relationship to other parts of the work, including clearances required for operation and maintenance. Submit drawings showing bolt-setting information, and foundation bolts prior to concrete foundation construction for all equipment indicated or required to have concrete foundations. Submit function designation of the equipment and any other requirements specified throughout this Section with the shop drawings. 1.4.6 Test Procedures
[Submit proposed test procedures and test schedules for the [ductwork leak test, and] performance tests of systems, at least 2 weeks prior to the start of related testing.] 1.5 DELIVERY, STORAGE, AND HANDLING
Protect stored equipment at the jobsite from the weather, humidity and SECTION 23 00 00 Page 9
123044
temperature variations, dirt and dust, or other contaminants. Additionally, cap or plug all pipes until installed. PART 2 2.1 PRODUCTS STANDARD PRODUCTS
Except for the fabricated duct, plenums and casings specified in paragraphs "Metal Ductwork" and "Plenums and Casings for Field-Fabricated Units", provide components and equipment that are standard products of manufacturers regularly engaged in the manufacturing of products that are of a similar material, design and workmanship. This requirement applies to all equipment, including diffusers, registers, fire dampers, and balancing dampers. a. Standard products are defined as components and equipment that have been in satisfactory commercial or industrial use in similar applications of similar size for at least two years before bid opening. Prior to this two year period, these standard products shall have been sold on the commercial market using advertisements in manufacturers' catalogs or brochures. These manufacturers' catalogs, or brochures shall have been copyrighted documents or have been identified with a manufacturer's document number. Provide equipment items that are supported by a service organization. Where applicable, provide equipment that is an ENERGY STAR Qualified product or a Federal Energy Management Program (FEMP) designated product. IDENTIFICATION PLATES
b.
c.
2.2
In addition to standard manufacturer's identification plates, provide engraved laminated phenolic identification plates for each piece of mechanical equipment. Identification plates are to designate the function of the equipment. Submit designation with the shop drawings. Identification plates shall be three layers, black-white-black, engraved to show white letters on black background. Letters shall be upper case. Identification plates 1-1/2-inches high and smaller shall be 1/16-inch thick, with engraved lettering 1/8-inch high; identification plates larger than 1-1/2-inches high shall be 1/8-inch thick, with engraved lettering of suitable height. Identification plates 1-1/2-inches high and larger shall have beveled edges. Install identification plates using a compatible adhesive. 2.3 EQUIPMENT GUARDS AND ACCESS
Fully enclose or guard belts, pulleys, chains, gears, couplings, projecting setscrews, keys, and other rotating parts exposed to personnel contact according to OSHA requirements. Properly guard or cover with insulation of a type specified, high temperature equipment and piping exposed to contact by personnel or where it creates a potential fire hazard. The requirements for [catwalks,] [operating platforms,] [ladders,] [and] [guardrails] are specified in Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS. 2.4 a. ELECTRICAL WORK Provide motors, controllers, integral disconnects, contactors, and controls with their respective pieces of equipment, except controllers SECTION 23 00 00 Page 10
123044
indicated as part of motor control centers. Provide electrical equipment, including motors and wiring, as specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Provide manual or automatic control and protective or signal devices required for the operation specified and control wiring required for controls and devices specified, but not shown. For packaged equipment, include manufacturer provided controllers with the required monitors and timed restart. b. For single-phase motors, provide high-efficiency type, fractional-horsepower alternating-current motors, including motors that are part of a system, in accordance with NEMA MG 11. Integral size motors shall be the premium efficiency type in accordance with NEMA MG 1. For polyphase motors, provide squirrel-cage medium induction motors, including motors that are part of a system , and that meet the efficiency ratings for premium efficiency motors in accordance with NEMA MG 1. Select premium efficiency polyphase motors in accordance with NEMA MG 10. Provide motors in accordance with NEMA MG 1 and of sufficient size to drive the load at the specified capacity without exceeding the nameplate rating of the motor. Provide motors rated for continuous duty with the enclosure specified. Provide motor duty that allows for maximum frequency start-stop operation and minimum encountered interval between start and stop. Provide motor torque capable of accelerating the connected load within 20 seconds with 80 percent of the rated voltage maintained at motor terminals during one starting period. Provide motor starters complete with thermal overload protection and other necessary appurtenances. Fit motor bearings with grease supply fittings and grease relief to outside of the enclosure. [Where two-speed or variable-speed motors are indicated, solid-state variable-speed controllers are allowed to accomplish the same function. Use solid-state variable-speed controllers for motors rated 10 hp or less and adjustable frequency drives for larger motors.] [ Provide variable frequency drives for motors as specified in Division 26.Section 26 29 23 VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600 VOLTS.] ANCHOR BOLTS
c.
d.
e.
2.5
Provide anchor bolts for equipment placed on concrete equipment pads or on concrete slabs. Bolts to be of the size and number recommended by the equipment manufacturer and located by means of suitable templates. Installation of anchor bolts shall not degrade the surrounding concrete. 2.6 SEISMIC ANCHORAGEAT/FP BRACING
Anchor equipment in accordance with applicable seismic criteria for the area and as defined in SMACNA 1650All overhead utilities and fixtures weighing 31 lbs or more (excluding distributed systems such as piping networks that collectively exceed that weight) shall be supported using rigid or flexible systems to minimize the likleyhood that they will fall and injure building occupants. Equipment mountings shall be capable of resisting forces of 0.5 times the equipment weight in any horizontal direction and 1.5 times the equipment weight in the downward direction. Refer to ATFP Equipment Bracing detail on drawings.
SECTION 23 00 00
Page 11
123044
2.7
PAINTING
Paint equipment units in accordance with approved equipment manufacturer's standards unless specified otherwise. Field retouch only if approved. Otherwise, return equipment to the factory for refinishing. 2.8 INDOOR AIR QUALITY
Provide equipment and components that comply with the requirements of ASHRAE 62.1 unless more stringent requirements are specified herein. 2.9 2.9.1 DUCT SYSTEMS Metal Ductwork
Provide metal ductwork construction, including all fittings and components, that complies with SMACNA 1966, as supplemented and modified by this specification . a. Ductwork shall be constructed meeting the requirements for the duct system static pressure specified in APPENDIX D of Section 23 05 93 TESTING, ADJUSTING AND BALANCING FOR HVAC.
[a][b]. Provide radius type elbows with a centerline radius of 1.5 times the width or diameter of the duct where space permits. Otherwise, elbows having a minimum radius equal to the width or diameter of the duct or square elbows with factory fabricated turning vanes are allowed.
c.
Provide ductwork that meets the requirements of Seal Class A. Provide ductwork in VAV systems upstream of the VAV boxes that meets the requirements of Seal Class A. fire hazard classification INSULATION FOR MECHANICAL SYSTEMS distribution and ambient Do not use pressure sensitive
[c][d]. Provide sealants that conform to specified in Section 23 07 00 THERMAL and are suitable for the range of air temperatures to which it is exposed. tape as a sealant.
[d][e]. Make spiral lock seam duct, and flat oval with duct sealant and lock with not less than 3 equally spaced drive screws or other approved methods indicated in SMACNA 1966. Apply the sealant to the exposed male part of the fitting collar so that the sealer is on the inside of the joint and fully protected by the metal of the duct fitting. Apply one brush coat of the sealant over the outside of the joint to at least 2 inch band width covering all screw heads and joint gap. Dents in the male portion of the slip fitting collar are not acceptable. Fabricate outdoor air intake ducts and plenums with watertight soldered or brazed joints and seams. 2.10.1.1 a. Metallic Flexible Duct
Provide duct that conforms to UL 181 and NFPA 90A with factory-applied insulation, vapor barrier, and end connections. Provide duct assembly that does not exceed 25 for flame spread and 50 for smoke developed. Provide ducts designed for working pressures of two inches water gauge positive and 1.5 inches water gauge negative. Provide flexible round duct length that does not exceed five feet. Secure connections by SECTION 23 00 00 Page 12
123044
applying adhesive for two inches over rigid duct, apply flexible duct two inches over rigid duct, apply metal clamp, and provide minimum of three No. 8 sheet metal screws through clamp and rigid duct. b. Inner duct core: Provide interlocking spiral or helically corrugated flexible core constructed of zinc-coated steel, aluminum, or stainless steel; or constructed of inner liner of continuous galvanized spring steel wire helix fused to continuous, fire-retardant, flexible vapor barrier film, inner duct core. Insulation: Provide inner duct core that is insulated with mineral fiber blanket type flexible insulation, minimum of one inch thick. Provide insulation covered on exterior with manufacturer's standard fire retardant vapor barrier jacket for flexible round duct. Insulated Nonmetallic Flexible Duct Runouts
c.
2.9.1.1
Use flexible duct runouts only where indicated. Runout length is indicated on the drawings, and is not to exceed 5 feet. Provide runouts that are preinsulated, factory fabricated, and that comply with NFPA 90A and UL 181. Provide either field or factory applied vapor barrier. Provide not less than 20 ounce glass fabric duct connectors coated on both sides with neoprene. Where coil induction or high velocity units are supplied with vertical air inlets, use a streamlined, vaned and mitered elbow transition piece for connection to the flexible duct or hose. Provide a die-stamped elbow and not a flexible connector as the last elbow to these units other than the vertical air inlet type. Insulated flexible connectors are allowed as runouts. Provide insulated material and vapor barrier that conform to the requirements of Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. Do not expose the insulation material surface to the air stream. 2.9.1.2 General Service Duct Connectors
Provide a flexible duct connector approximately 6 inches in width where sheet metal connections are made to fans or where ducts of dissimilar metals are connected. For round/oval ducts, secure the flexible material by stainless steel or zinc-coated, iron clinch-type draw bands. For rectangular ducts, install the flexible material locked to metal collars using normal duct construction methods. Provide a composite connector system that complies with NFPA 701 and is classified as "flame-retarded fabrics" in UL Bld Mat Dir. 2.9.1.3 High Temperature Service Duct Connections
Provide material that is approximately 3/32 inch thick, 35 to 40-ounce per square yard weight, plain weave fibrous glass cloth with, nickel/chrome wire reinforcement for service in excess of 1200 degrees F. 2.10.1.5 Aluminum Ducts
ASTM B 209, alloy 3003-H14 for aluminum sheet and alloy 6061-T6 or equivalent strength for aluminum connectors and bar stock. 2.10.1.6 Copper Sheets
ASTM B 152/B 152M, light cold rolled temper.
SECTION 23 00 00
Page 13
123044
2.10.1.7 ASTM A167 2.9.2
Corrosion Resisting (Stainless) Steel Sheets
Duct Access Doors
Provide hinged access doors conforming to SMACNA 1966 in ductwork and plenums where indicated and at all air flow measuring primaries, automatic dampers, fire dampers, coils, thermostats, and other apparatus requiring service and inspection in the duct system. Provide access doors upstream and downstream of air flow measuring primaries and heating and cooling coils. Provide doors that are a minimum 15 by 18 inches, unless otherwise shown. Where duct size does not accommodate this size door, make the doors as large as practicable. Equip doors 24 by 24 inches or larger with fasteners operable from inside and outside the duct. Use insulated type doors in insulated ducts. 2.9.3 Fire Dampers
Use 1.5 hour rated fire dampers unless otherwise indicated. Provide fire dampers that conform to the requirements of NFPA 90A and UL 555. Perform the fire damper test as outlined in NFPA 90A. Provide a pressure relief door upstream of the fire damper. If the ductwork connected to the fire damper is to be insulated then provide a factory installed pressure relief damper. Provide automatic operating fire dampers with a dynamic rating suitable for the maximum air velocity and pressure differential to which it is subjected. Provide fire dampers approved for the specific application, and install according to their listing. Equip fire dampers with a steel sleeve or adequately sized frame installed in such a manner that disruption of the attached ductwork, if any, does not impair the operation of the damper. Equip sleeves or frames with perimeter mounting angles attached on both sides of the wall or floor opening. Construct ductwork in fire-rated floor-ceiling or roof-ceiling assembly systems with air ducts that pierce the ceiling of the assemblies in conformance with UL Fire Resistance. Provide [curtain type with damper blades] [in the air stream] [out of the air stream] [or] [single blade type] [or] [multi-blade type] fire dampers. Install dampers that do not reduce the duct or the air transfer opening cross-sectional area. Install dampers so that the centerline of the damper depth or thickness is located in the centerline of the wall, partition or floor slab depth or thickness. Unless otherwise indicated, comply with the installation details given in SMACNA 1819 and in manufacturer's instructions for fire dampers. Perform acceptance testing of fire dampers according to paragraph Fire Damper Acceptance Test and NFPA 90A. 2.9.4 Manual Balancing Dampers a. Furnish manual balancing dampers with accessible operating mechanisms. Use chromium plated operators (with all exposed edges rounded) in finished portions of the building. Provide manual volume control dampers that are operated by locking-type quadrant operators. b. Unless otherwise indicated, provide opposed blade type multileaf dampers with maximum blade width of 12 inches. Provide access doors or panels for all concealed damper operators and locking setscrews. Provide access doors or panels in hard ceilings, partitions and walls for access to all concealed damper operators and damper locking setscrews. Coordinate location of doors or panels with other affected contractors.
SECTION 23 00 00
Page 14
123044
c. Provide stand-off mounting brackets, bases, or adapters not less than the thickness of the insulation when the locking-type quadrant operators for dampers are installed on ducts to be thermally insulated, to provide clearance between the duct surface and the operator. Stand-off mounting items shall be integral with the operator or standard accessory of the damper manufacturer. 2.9.4.1 a. Square or Rectangular Dampers 12 inches and Less
Duct Height (1)
Frames: Maximum 19 inches in width, maximum 12 inches in height; minimum of 20 gauge galvanized steel, minimum of 3 inches long. More than 19 inches in width, maximum 12 inches in height; Minimum of 16 gauge galvanized steel, minimum of 3 inches long.
(2)
Single Leaf Blades: Maximum 19 inches in width, maximum 12 inches in height; Minimum of 20 gauge galvanized steel, minimum of 3 inches long. More than 19 inches in width, maximum 12 inches in height; Minimum of 16 gauge galvanized steel, minimum of 3 inches long.
(3)
Blade Axles: To support the blades of round dampers, provide galvanized steel shafts supporting the blade the entire duct diameter frame-to-frame. Axle shafts shall extend through standoff bracket and hand quadrant. Maximum 19 inches in width, maximum 12 inches in height; Galvanized steel, minimum of 3/8 inch square shaft. More than 19 inches in width, maximum 12 inches in height; Galvanized steel, minimum of 1/2 inch square shaft.
(4)
Axle Bearings: Support the shaft on each end at the frames with shaft bearings. Shaft bearings configuration shall be a pressed fit to provide a tight joint between blade shaft and damper frame. Maximum 19 inches in width, maximum 12 inches in height; solid nylon, or equivalent solid plastic, or oil-impregnated bronze bearings. More than19 inches in width, maximum 12 inches in height; oil-impregnated bronze bearings.
(5)
Control Shaft/Hand Quadrant: Provide dampers with accessible locking-type control shaft/hand quadrant operators. Provide stand-off mounting brackets, bases, or adapters for the locking-type quadrant operators on dampers installed on ducts to be thermally insulated. Stand-off distance shall be a minimum of 50 mm 2 inches off the metal duct surface. Stand-off mounting items shall be integral with the operator or standard accessory of the damper manufacturer. SECTION 23 00 00 Page 15
123044
(6) b.
Finish:
Mill Galvanized
Duct Height Greater than 12 inches Provide dampers with multi-leaf opposed-type blades. (1) Frames: Maximum 48 inches in height; maximum48 inches in 16 gauge galvanized steel, minimum of 5.5 inches long.
width; minimum of
(2)
Blades: Minimum of 16 gauge galvanized steel; 6 inch nominal width. Blade Axles: To support the blades of round dampers, provide galvanized square steel shafts supporting the blade the entire duct diameter frame-to-frame. Axle shafts shall extend through standoff bracket and hand quadrant. Axle Bearings: Support the shaft on each end at the frames with shaft bearings constructed of oil-impregnated bronze, or solid nylon, or a solid plastic equivalent to nylon. Shaft bearings configuration shall be a pressed fit to provide a tight joint between blade shaft and damper frame. Blade Actuator: Minimum 1/2 inch diameter galvanized steel.
(3)
(4)
(5) (6)
Blade Actuator Linkage: Mill Galvanized steel bar and crank plate with stainless steel pivots. Control Shaft/Hand Quadrant: Provide dampers with accessible locking-type control shaft/hand quadrant operators. Provide stand-off mounting brackets, bases, or adapters for the locking-type quadrant operators on dampers installed on ducts to be thermally insulated. Stand-off distance shall be a minimum of 50 mm 2 inches off the metal duct surface. Stand-off mounting items shall be integral with the operator or standard accessory of the damper manufacturer.
(7)
(8) 2.9.4.2
Finish:
Mill Galvanized
Round Dampers
a. Frames: 4 to 20 inches size: Minimum of 20 gauge galvanized steel, minimum of 10 inches long. size: Minimum of 20 gauge galvanized steel, minimum of 10 inches long. 32 to 40 inches size: Minimum of 16 gauge galvanized steel, minimum of 10 inches long. b. Blades: SECTION 23 00 00 Page 16
123044
4 to 20 inches size: Minimum of 20 gauge galvanized steel 22 to 30 inches size: Minimum of 16 gauge galvanized steel 32 to 40 inches size: Minimum of 10 gauge galvanized steel c. Blade Axles To support the blades of round dampers, provide galvanized steel shafts supporting the blade the entire duct diameter frame-to-frame. Axle shafts shall extend through standoff bracket and hand quadrant. 4 to 20 inches size: Minimum of 3/8 inch square shaft. 22 to 30 inches size: Minimum of 1/2 inch square shaft. 32 to 40 inches size: Minimum of 3/4 inch square shaft. d. Axle Bearings: Support the shaft on each end at the frames with shaft bearings constructed of oil-impregnated bronze, or solid nylon, or a solid plastic equivalent to nylon. Shaft bearings configuration shall be a pressed fit to provide a tight joint between blade shaft and damper frame. 4 to 20 inches size: solid nylon, or equivalent solid plastic, or oil-impregnated bronze. 22 to 30 inches size: solid nylon, or equivalent solid plastic, or oil-impregnated bronze. 32 to 40 inches size: oil-impregnated bronze, or stainless steel sleeve bearing e. Control Shaft/Hand Quadrant: Provide dampers with accessible locking-type control shaft/hand quadrant operators. Provide stand-off mounting brackets, bases, or adapters for the locking-type quadrant operators on dampers installed on ducts to be thermally insulated. Stand-off distance shall be a minimum of 2 inches off the metal duct surface. Stand-off mounting items shall be integral with the operator or standard accessory of the damper manufacturer. f. 2.9.5 Finish: Mill Galvanized
Automatic Balancing Dampers
Provide dampers as specified in paragraph SUPPLEMENTAL COMPONENTS/SERVICES, subparagraph CONTROLS. 2.10.7 Automatic Smoke-Fire Dampers
Multiple blade type, 180 degrees F fusible fire damper link; smoke damper assembly to include pneumatically powered operator. UL 555 as a 1.5 hour rated fire damper; further qualified under UL 555S as a leakage rated damper. Provide a leakage rating under UL 555S that is no higher than Class [II][ or ][III] at an elevated temperature Category B ( 250 degrees F for 30 minutes ). Ensure that pressure drop in the damper open position SECTION 23 00 00 Page 17
123044
does not exceed 0.1 inch water gauge with average duct velocities of 2500 fpm. 2.10.8 Automatic Smoke Dampers
UL listed multiple blade type, supplied by smoke damper manufacturer, with pneumatic damper operator as part of assembly. Qualified under UL 555S with a leakage rating no higher than Class [II][ or ][III] at an elevated temperature Category B ( 250 degrees F for 30 minutes ). Ensure that pressure drop in the damper open position does not exceed 0.1 inch water gauge with average duct velocities of 2500 fpm. 2.10.11 2.10.11.1 Plenums and Casings for Field-Fabricated Units Plenum and Casings
Fabricate and erect plenums and casings as shown in SMACNA 1966, as applicable. Construct system casing of not less than 16 gauge galvanized sheet steel. Furnish cooling coil drain pans with 1 inch threaded outlet to collect condensation from the cooling coils. Fabricate drain pans from not lighter than 16 gauge steel, galvanized after fabrication or of 18 gauge corrosion-resisting sheet steel conforming to ASTM A167, Type 304, welded and stiffened. Thermally insulate drain pans exposed to the atmosphere to prevent condensation. Coat insulation with a flame resistant waterproofing material. Provide separate drain pans for each vertical coil section, and a separate drain line for each pan. Size pans to ensure capture of entrained moisture on the downstream-air side of the coil. Seal openings in the casing, such as for piping connections, to prevent air leakage. Size the water seal for the drain to maintain a pressure of at least 2 inch water gauge greater than the maximum negative pressure in the coil space. 2.10.11.2 Casing
Terminate casings at the curb line and bolt each to the curb using galvanized angle, as indicated in SMACNA 1966. 2.10.11.3 Access Doors
Provide access doors in each section of the casing. Weld doorframes in place, gasket each door with neoprene, hinge with minimum of two brass hinges, and fasten with a minimum of two brass tension fasteners operable from inside and outside of the casing. Where possible, make doors 36 by 18 inches and locate them 18 inches above the floor. Where the space available does not accommodate doors of this size, use doors as large as the space accommodates. Swing doors so that fan suction or pressure holds doors in closed position, airtight. Provide a push-button station, located inside the casing, to stop the supply. 2.10.11.4 Factory-Fabricated Insulated Sheet Metal Panels
Factory-fabricated components are allowed for field-assembled units, provided all requirements specified for field-fabricated plenums and casings are met. Provide panels of modular design, pretested for structural strength, thermal control, condensation control, and acoustical control. Seal and insulate panel joints. Provide and gasket access doors to prevent air leakage. Provide panel construction that is not less than 20 gauge galvanized sheet steel, assembled with fasteners treated against corrosion. Provide standard length panels that deflect not more than 1/2 inch under operation. Construct details, including joint sealing, not SECTION 23 00 00 Page 18
123044
specifically covered, as indicated in SMACNA 1966. Construct the plenums and casings to withstand the specified internal pressure of the air systems. 2.10.11.5 Duct Liner
Unless otherwise specified, duct liner is not permitted. 2.10.12 a. Sound Attenuation Equipment
For systems with total pressure above 4 Inches Water Gauge: Provide sound attenuators on the discharge duct of each fan operating at a total pressure above 4 inch water gauge, and, when indicated, at the intake of each fan system. Provide sound attenuators elsewhere as indicated. Provide factory fabricated sound attenuators, tested by an independent laboratory for sound and performance characteristics. Provide a net sound reduction as indicated. Maximum permissible pressure drop is not to exceed 0.63 inch water gauge. Construct traps to be airtight when operating under an internal static pressure of 10 inch water gauge. Provide air-side surface capable of withstanding air velocity of 10,000 fpm. Certify that the equipment can obtain the sound reduction values specified after the equipment is installed in the system and coordinated with the sound information of the system fan to be provided. Provide sound absorbing material conforming to ASTM C 1071, Type I or II. Provide sound absorbing material that meets the fire hazard rating requirements for insulation specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. For connection to ductwork, provide a duct transition section. Factory fabricated double-walled internally insulated spiral lock seam and round duct and fittings designed for high pressure air system can be provided if complying with requirements specified for factory fabricated sound attenuators, in lieu of factory fabricated sound attenuators. Construct the double-walled duct and fittings from an outer metal pressure shell of zinc-coated steel sheet, 1 inch thick acoustical blanket insulation, and an internal perforated zinc-coated metal liner. Provide a sufficient length of run to obtain the noise reduction coefficient specified. Certify that the sound reduction value specified can be obtained within the length of duct run provided. Provide welded or spiral lock seams on the outer sheet metal of the double-walled duct to prevent water vapor penetration. Provide duct and fittings with an outer sheet that conforms to the metal thickness of high-pressure spiral and round ducts and fittings shown in SMACNA 1966. Provide acoustical insulation with a thermal conductivity "k" of not more than 0.27 Btu/inch/square foot/hour/degree F at 75 degrees F mean temperature. Provide an internal perforated zinc-coated metal liner that is not less than 24 gauge with perforations not larger than 1/4 inch in diameter providing a net open area not less than 10 percent of the surface. For system with total pressure of 4 Inch Water Gauge and Lower: Use sound attenuators only where indicated. Provide factory fabricated sound attenuators that are constructed of galvanized steel sheets. Provide attenuator with outer casing that is not less than 22 gauge. Provide fibrous glass acoustical fill. Provide net sound reduction indicated. Obtain values on a test unit not less than 24 by 24 inches outside dimensions made by a certified nationally recognized independent acoustical laboratory. Provide air flow capacity as indicated or required. Provide pressure drop through the attenuator that does not exceed the value indicated, or that is not in excess of 15 percent of the total external static pressure of the air handling SECTION 23 00 00 Page 19
b.
123044
system, whichever is less. Acoustically test attenuators with metal duct inlet and outlet sections while under the rated air flow conditions. Include with the noise reduction data the effects of flanking paths and vibration transmission. Construct sound attenuators to be airtight when operating at the internal static pressure indicated or specified for the duct system, but in no case less than 2 inch water gauge. c. For acoustical duct liner: Use fibrous glass designed or flexible elastomeric duct liner for lining ductwork and conforming to the requirements of ASTM C 1071, Type I and II. Provide uniform density, graduated density, or dual density liner composition, as standard with the manufacturer. Provide not less than 1 inch thick coated lining. Where acoustical duct liner is used, provide the thermal equivalent of the insulation specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS for liner or combination of liner and insulation applied to the exterior of the ductwork. Increase duct sizes shown to compensate for the thickness of the lining used. [In lieu of sheet metal duct with field-applied acoustical lining, provide acoustically equivalent lengths of fibrous glass duct, elastomeric duct liner or factory fabricated double-walled internally insulated duct with perforated liner.] Diffusers, Registers, and Grilles
2.9.6
Provide factory-fabricated units of [steel][corrosion-resistant steel][ or ][aluminum] that distribute the specified quantity of air evenly over space intended without causing noticeable drafts, air movement faster than 50 fpm in occupied zone, or dead spots anywhere in the conditioned area. Provide outlets for diffusion, spread, throw, and noise level as required for specified performance. Certify performance according to ASHRAE 70. Provide sound rated and certified inlets and outlets according to ASHRAE 70. Provide sound power level as indicated. Provide diffusers and registers with volume damper with accessible operator, unless otherwise indicated; or if standard with the manufacturer, an automatically controlled device is acceptable. Provide opposed blade type volume dampers for all diffusers and registers, except linear slot diffusers. Provide linear slot diffusers with round or elliptical balancing dampers. Where the inlet and outlet openings are located less than 7 feet above the floor, protect them by a grille or screen according to NFPA 90A. 2.9.6.1 Diffusers
Provide diffuser types indicated. Furnish ceiling mounted units with anti-smudge devices, unless the diffuser unit minimizes ceiling smudging through design features. Provide diffusers with air deflectors of the type indicated. Provide air handling troffers or combination light and ceiling diffusers conforming to the requirements of UL Electrical Constructn for the interchangeable use as cooled or heated air supply diffusers or return air units. Install ceiling mounted units with rims tight against ceiling. Provide sponge rubber gaskets between ceiling and surface mounted diffusers for air leakage control. Provide suitable trim for flush mounted diffusers. For connecting the duct to diffuser, provide duct collar that is airtight and does not interfere with volume controller. Provide return or exhaust units that are similar to supply diffusers. 2.10.13.2 Perforated Plate Diffusers
Provide adjustable [one-way,] [two-way,] [three-way,][ or ][four-way] air SECTION 23 00 00 Page 20
123044
pattern controls as indicated. Provide diffuser faceplates that do not sag or deflect when operating under design conditions. 2.10.13.3 Linear Diffusers
Make joints between diffuser sections that appear as hairline cracks. Provide alignment slots for insertion of key strips or other concealed means to align exposed butt edges of diffusers.[ Equip with plaster frames when mounted in plaster ceiling.] Do not use screws and bolts in exposed face of frames or flanges. Metal-fill and ground smooth frames and flanges exposed below ceiling. Furnish separate pivoted or hinged adjustable air-volume-damper and separate air-deflection blades. 2.9.6.2 Registers and Grilles
Provide units that are four-way directional-control type, except provide return and exhaust registers that are fixed horizontal or vertical louver type similar in appearance to the supply register face. Furnish registers with sponge-rubber gasket between flanges and wall or ceiling. Install wall supply registers at least 6 inches below the ceiling unless otherwise indicated. Locate return and exhaust registers 6 inches above the floor unless otherwise indicated. Achieve four-way directional control by a grille face which can be rotated in 4 positions or by adjustment of horizontal and vertical vanes. Provide grilles as specified for registers, without volume control damper. Provide return air filter grille. 2.9.6.3 Registers
Double-deflection supply registers.[ Provide manufacturer-furnished volume dampers. Provide volume dampers of the group-operated, opposed-blade type and key adjustable by inserting key through face of register. Operating mechanism shall not project through any part of the register face. Automatic volume control devices are acceptable.][ Provide exhaust and return registers as specified for supply registers, except provide exhaust and return registers that have a single set of nondirectional face bars or vanes having the same appearance as the supply registers.][ Set face bars or vanes at [45_____] degrees.] 2.9.7 Louvers
Provide louvers for installation in exterior walls that are associated with the air supply and distribution system as specified in Section [07 60 00 FLASHING AND SHEET METAL] [08 91 00 METAL [WALL][ AND ][DOOR] LOUVERS]. 2.9.8 Air Vents, Penthouses, and Goosenecks
Fabricate air vents, penthouses, and goosenecks from galvanized steel [or aluminum] sheets with galvanized[ or aluminum] structural shapes. Provide sheet metal thickness, reinforcement, and fabrication that conform to SMACNA 1966. Accurately fit and secure louver blades to frames. Fold or bead edges of louver blades for rigidity and baffle these edges to exclude driving rain. Provide air vents, penthouses, and goosenecks with bird screen. Air Vents, Penthouses and Goosenecks are be high wind certified per ICC IBC and installed/anchored to withstand high wind conditions. 2.9.9 Bird Screens and Frames
Provide bird screens that conform to ASTM E 2016, No. 2 mesh, aluminum or stainless steel. Provide "medium-light" rated aluminum screens. Provide SECTION 23 00 00 Page 21
123044
"light" rated stainless steel screens. Provide removable type frames fabricated from either stainless steel or extruded aluminum. 2.10.17 Radon Exhaust Ductwork
Fabricate radon exhaust ductwork installed in or beneath slabs from Schedule 40 PVC pipe that conforms to ASTM D 1785. Provide fittings that conform to ASTM D 2466. Use solvent cement conforming to ASTM D 2564 to make joints. Otherwise provide metal radon exhaust ductwork as specified herein. 2.10 2.10.1 AIR SYSTEMS EQUIPMENT Fans
Test and rate fans according to AMCA 210. Calculate system effect on air moving devices in accordance with AMCA 201 where installed ductwork differs from that indicated on drawings. Install air moving devices to minimize fan system effect. Where system effect is unavoidable, determine the most effective way to accommodate the inefficiencies caused by system effect on the installed air moving device. The sound power level of the fans shall not exceed 85 dBA when tested according to AMCA 300 and rated in accordance with AMCA 301. Provide all fans with an AMCA seal. Connect fans to the motors either directly or indirectly with V-belt drive. Use V-belt drives designed for not less than [150] [140] [120] percent of the connected driving capacity. Provide variable pitch motor sheaves for 15 hp and below, and fixed pitch as defined by AHRI Guideline D. Select variable pitch sheaves to drive the fan at a speed which can produce the specified capacity when set at the approximate midpoint of the sheave adjustment. When fixed pitch sheaves are furnished, provide a replaceable sheave when needed to achieve system air balance. Provide motors for V-belt drives with adjustable rails or bases. Provide removable metal guards for all exposed V-belt drives, and provide speed-test openings at the center of all rotating shafts. Provide fans with personnel screens or guards on both suction and supply ends, except that the screens need not be provided, unless otherwise indicated, where ducts are connected to the fan. Provide fan and motor assemblies with vibration-isolation supports or mountings as indicated. Use vibration-isolation units that are standard products with published loading ratings. Select each fan to produce the capacity required at the fan static pressure indicated. Provide sound power level as indicated. Obtain the sound power level values according to AMCA 300. Provide standard AMCA arrangement, rotation, and discharge as indicated. Provide power ventilators that conform to UL 705 and have a UL label. 2.10.1.1 Centrifugal Fans
Provide fully enclosed, single-width single-inlet, or double-width double-inlet centrifugal fans, with AMCA Pressure Class I, II, or III as required or indicated for the design system pressure. Provide impeller wheels that are rigidly constructed and accurately balanced both statically and dynamically. [Provide forward curved or backward-inclined airfoil design fan blades in wheel sizes up to 30 inches. Provide backward-inclined airfoil design fan blades for wheels over 30 inches in diameter]. [Provide open-wheel radial type booster fans for exhaust dryer systems, and fans suitable for conveying lint and the temperatures encountered. Equip the fan shaft with a heat slinger to dissipate heat buildup along the shaft. Install an access (service) door to facilitate maintenance to these fans.] Provide fan wheels over 36 inches in diameter with overhung pulleys and a bearing on each side of the wheel. Provide fan SECTION 23 00 00 Page 22
123044
wheels 36 inches or less in diameter that have one or more extra long bearings between the fan wheel and the drive. Provide sleeve type, self-aligning and self-oiling bearings with oil reservoirs, or precision self-aligning roller or ball-type with accessible grease fittings or permanently lubricated type. Connect grease fittings to tubing for serviceability from a single accessible point. Provide L50 rated bearing life at not less than 200,000 hours as defined by ABMA 9 and ABMA 11. Provide steel, accurately finished fan shafts, with key seats and keys for impeller hubs and fan pulleys. Provide fan outlets of ample proportions, designed for the attachment of angles and bolts for attaching flexible connections. Provide[[manually] [automatically] operated inlet vanes on suction inlets. Provide [manually] [automatically] operated outlet dampers. ] Unless otherwise indicated, provide motors that do not exceed 1800 rpm and have [open] [dripproof] [totally enclosed] [explosion-proof] enclosures. [Provide [manual] [magnetic] [across-the-line] [ reduced-voltage-start] type motor starters with [general-purpose] [weather-resistant] [watertight] enclosure.] [Provide remote manual switch with pilot indicating light where indicated.] 2.10.1.2 In-Line Centrifugal Fans
Provide in-line fans with centrifugal backward inclined blades, stationary discharge conversion vanes, internal and external belt guards, and adjustable motor mounts. Mount fans in a welded tubular casing. Provide a fan that axially flows the air in and out. Streamline inlets with conversion vanes to eliminate turbulence and provide smooth discharge air flow. Enclose and isolate fan bearings and drive shafts from the air stream. Provide precision, self aligning ball or roller type fan bearings that are sealed against dust and dirt and are permanently lubricated. Provide L50 rated bearing life at not less than 200,000 hours as defined by ABMA 9 and ABMA 11.[ Provide motors with [open][dripproof][totally enclosed] [explosion-proof] enclosure.] [Provide [manual] [magnetic] motor starters across-the-line with [general-purpose] [weather-resistant] [explosion-proof] enclosures.][ Provide remote manual switch with pilot indicating light where indicated.] 2.11.1.3 Axial Flow Fans
Provide axial flow fans complete with drive components and belt guard, with steel housing, cast fan wheel, cast or welded steel diffusers, fan shaft, bearings, and mounting frame as a factory-assembled unit. Provide fan wheels that are dynamically balanced and keyed to the fan shaft, with radially projecting blades of airfoil cross-section. Enclose and isolate fan bearings and drive shafts from the air stream. Permanently lubricate fan bearings or provide them with accessible grease fittings. Provide precision self-aligning ball or roller type fan bearings that are sealed against dust and dirt. Provide fan bearings that have a L50 rated bearing life at not less than 200,000 hours of operation as defined by ABMA 9 and ABMA 11. Provide fan inlets with an aerodynamically shaped bell and an inlet cone. Install diffuser or straightening vanes at the fan discharge to minimize turbulence and provide smooth discharge air flow. Furnish fan unit with [inlet and outlet flanges,] [inlet screen,] [duct equalizer section,] and [manual] [automatic] operation adjustable inlet vanes. Unless otherwise indicated, provide motors that do not exceed 1800 rpm and have [open] [dripproof] [totally enclosed] [explosion-proof] enclosure. [Provide [manual] [magnetic] motor starters across-the-line with [general-purpose] [weather-resistant] [explosion-proof] enclosure.] [Provide remote manual switch with pilot indicating light where indicated.]
SECTION 23 00 00
Page 23
123044
2.10.1.3
Panel Type Power Wall Ventilators
Provide propeller type fans, assembled on a reinforced metal panel with venturi opening spun into panel. Provide direct or V-belt driven fans with wheels less than 24 inches in diameter and provide V-belt driven fans with wheels 24 inches in diameter and larger. Provide fans with wall mounting collar. Provide lubricated bearings. Equip fans with wheel and motor side metal or wire guards which have a corrosion-resistant finish. Provide [ dripproof][totally enclosed fan cooled][explosion-proof] type motor enclosure. Install [gravity][motor operated] backdraft dampers where indicated. 2.11.1.5 Centrifugal Type Power Wall Ventilators
Provide [direct][ or ][V-belt] driven centrifugal type fans with backward inclined, non-overloading wheel. Provide removable and weatherproof motor housing. Provide unit housing that is designed for sealing to building surface and for discharge and condensate drippage away from building surface. Construct housing of heavy gauge aluminum. Equip unit with an [aluminum or plated steel wire discharge bird screen,] [disconnect switch,] [[anodized aluminum][stainless steel] wall grille,] [manufacturer's standard [gravity][motor-operated] damper,] an airtight and liquid-tight metallic wall sleeve. Provide [totally enclosed fan cooled] [dripproof] [explosion-proof] type motor enclosure. Use only lubricated bearings. 2.11.1.6 Centrifugal Type Power Roof Ventilators
Provide [direct][ or ][V-belt] driven centrifugal type fans with backward inclined, non-overloading wheel. Provide hinged or removable and weatherproof motor compartment housing, constructed of heavy gauge aluminum. Provide fans with [birdscreen,] [disconnect switch,] [[gravity] [motorized] dampers,] [sound curb,] [roof curb,] and [extended base]. Provide [dripproof] [explosion-proof] type motor enclosure. Provide centrifugal type kitchen exhaust fans according to UL 705, fitted with V-belt drive, round hood, and windband upblast discharge configuration, integral residue trough and collection device, with motor and power transmission components located in outside positively air ventilated compartment. Use only lubricated bearings. 2.11.1.7 Propeller Type Power Roof Ventilators
Provide [direct][ or ][V-belt] driven fans. Provide hinged or removable weathertight fan housing, fitted with framed rectangular base constructed of aluminum or galvanized steel. Provide [totally enclosed fan cooled] [explosion-proof] type motors. Furnish motors with nonfusible, horsepower rated, manual disconnect mount on unit. Furnish fans with [gravity] [motor operated] dampers, [birdscreen][sound curb][roof curb]. Use only lubricated bearings. 2.11.1.8 Air-Curtain Fans
Provide fans that conform to AMCA 220 with AMCA seal. Furnish air curtains with a weatherproof housing constructed of high impact plastic or minimum 18 gauge rigid welded steel. Provide backward curved, non-overloading, centrifugal type fan wheels, accurately balanced statically and dynamically. Provide motors with totally enclosed fan cooled enclosures. Provide remote manual type motor starters with weather-resistant enclosure actuated when the doorway served is open. Provide air curtains that attain the air velocities specified within 2 seconds following activation. SECTION 23 00 00 Page 24
123044
Provide bird screens at air intake and discharge openings. Provide air curtain unit or a multiple unit installation that is at least as wide as the opening to be protected. Provide the air discharge openings to permit outward adjustment of the discharge air. Place installation and adjust according to the manufacturer's written recommendation. Furnish directional controls on air curtains for service windows for easy clean or convenient removal. Design air curtains to prevent the adjustment of the air velocities specified. Make the interior surfaces of the air curtain units accessible for cleaning. Provide certified test data indicating that the fan can provide the air velocities required when fan is mounted as indicated. Provide air curtains designed as fly fans unless otherwise indicated. [Provide air curtains designed for use in service entranceways that develop an air curtain not less than 3 inches thick at the discharge nozzle. Provide air velocity that is not less than 1600 fpm across the entire entryway when measured 3 feet above the floor.] [Provide air curtains designed for use on customer entranceways that develop an air curtain not less than 8 inches thick at the discharge opening. Provide velocity that is not less than 600 fpm across the entire entryway when measured 3 feet above the floor. Equip recirculating type air curtains with readily removable filters, or design the filters for in-position cleaning. Provide readily accessible and easily cleanable air capture compartment or design for in-position cleaning.] [Provide air curtains designed for use on service windows that develop an air curtain not less than 8 inches thick at the discharge opening. Provide air velocity that is not less than 600 fpm across the entire opening of the service window measured 3 feet below the air discharge opening.] 2.10.1.4 Ceiling Exhaust Fans
Provide centrifugal type, direct driven suspended cabinet-type ceiling exhaust fans. Provide fans with acoustically insulated housing. Provide chatter-proof backdraft damper. Provide egg-crate design or louver design integral face grille. Mount fan motors on vibration isolators. Furnish unit with mounting flange for hanging unit from above. Provide U.L. listed fans. 2.10.2 Coils
Provide fin-and-tube type coils constructed of seamless [copper][red brass] tubes and [aluminum][ or ][copper] fins mechanically bonded or soldered to the tubes.[ Provide copper tube wall thickness that is a minimum of [0.016 ][0.020][0.024] inches].[ Provide red brass tube wall thickness that is a minimum of [0.035] [0.049] inches]. [Provide aluminum fins that are [0.0055 ][0.0075] inch minimum thickness.][ Provide copper fins that are 0.0045 inch minimum thickness.] Provide casing and tube support sheets that are not lighter than 16 gauge galvanized steel, formed to provide structural strength. When required, provide multiple tube supports to prevent tube sag. Test each coil at the factory under water at not less than 400 psi air pressure and make suitable for 200 psi working pressure and 300 degrees F operating temperature unless otherwise stated. Mount coils for counterflow service. Rate and certify coils to meet the requirements of AHRI 410. 2.10.2.1 Water Coils
Install water coils with a pitch of not less than 1/8 inch/foot of the tube length toward the drain end. Use headers constructed of cast iron, welded steel or copper. Furnish each coil with a plugged vent and drain connection extending through the unit casing. Provide removable water SECTION 23 00 00 Page 25
123044
coils with drain pans. 2.11.2.3 Steam Heating Coils
Construct steam coils from cast semisteel, welded steel or copper headers, and [red brass][copper] tubes. Construct headers from cast iron, welded steel or copper. Provide fin tube and header section that float within the casing to allow free expansion of tubing for coils subject to high pressure steam service. Provide each coil with a field or factory installed vacuum breaker. Provide single-tube type coils with tubes not less than 1/2 inch outside diameter, except for steam preheat coils. Provide supply headers that distribute steam evenly to all tubes at the indicated steam pressure. Factory test coils to ensure that, when supplied with a uniform face velocity, temperature across the leaving side is uniform with a maximum variation of no more than 5 percent. 2.11.2.4 Steam Preheat (Nonfreeze) Coils
Provide steam-distribution-tube type steam (nonfreeze) coils with condensing tubes not less than 1 inch outside diameter for tube lengths 60 inches and over and 1/2 inch outside diameter for tube lengths under 60 inches. Construct headers from cast iron, welded steel, or copper. Provide distribution tubes that are not less than 5/8 inch outside diameter for tube lengths 60 inches and over and 3/8 inch outside diameter for tube lengths under 60 inches with orifices to discharge steam to condensing tubes. Install distribution tubes concentric inside of condensing tubes and hold securely in alignment. Limit maximum length of a single coil to 144 inches. Factory test coils to ensure that, when supplied with a uniform face velocity, temperature across the leaving side is uniform with a maximum variation of no more than 5 percent. 2.11.2.5 Electric Heating Coil
Provide an electric duct heater coil in accordance with UL 1995 and NFPA 70. Provide duct- or unit-mounted coil. Provide [nickel chromium resistor, single stage, strip] [nickel chromium resistor, single stage, strip or stainless steel, fin tubular] type coil. Provide coil with a built-in or surface-mounted high-limit thermostat interlocked electrically so that the coil cannot be energized unless the fan is energized. Provide galvanized steel or aluminum coil casing and support brackets. Mount coil to eliminate noise from expansion and contraction and for complete accessibility for service. 2.10.2.2 Eliminators
Equip each cooling coil having an air velocity of over 400 fpm through the net face area with moisture eliminators, unless the coil manufacturer guarantees, over the signature of a responsible company official, that no moisture can be carried beyond the drip pans under actual conditions of operation. Construct of minimum 24 gage [zinc-coated steel] [copper] [copper nickel] [or] [stainless steel], removable through the nearest access door in the casing or ductwork. Provide eliminators that have not less than two bends at 45 degrees and are spaced not more than 2-1/2 inches center-to-center on face. Provide each bend with an integrally formed hook as indicated in the SMACNA 1884. 2.11.2.7 Sprayed Coil Dehumidifiers
Provide assembly with reinforced, braced, and externally insulated SECTION 23 00 00 Page 26
123044
galvanized steel casing, vertical in-line spray pump, bronze self-cleaning spray nozzles, galvanized steel pipe spray headers, adjustable float valve with replaceable neoprene seat, manufacturer's standard cooling coil, and welded black steel drain tank. Provide overflow drain, make-up, and bleed connection. 2.10.2.3 Corrosion Protection for Coastal Installations
[Provide phenolic coating or other manufacturer applied coating system to all outdoor heat transfer coils. Coating shall be able to withstand the ASTM B 117 3000 hour salt spray resistance test. Heat transfer rating of coils should be as installed after coating has been applied._____] 2.10.3 Air Filters
List air filters according to requirements of UL 900, except list high efficiency particulate air filters of 99.97 percent efficiency by the DOP Test method under the Label Service to meet the requirements of UL 586. 2.10.3.1 Extended Surface Pleated Panel Filters
Provide 2 inch depth, sectional, disposable type filters of the size indicated with a MERV of 8 when tested according to ASHRAE 52.2. Provide initial resistance at 500 fpm that does not exceed 0.36 inches water gauge. Provide UL Class 2 filters, and nonwoven cotton and synthetic fiber mat media. Attach a wire support grid bonded to the media to a moisture resistant fiberboard frame. Bond all four edges of the filter media to the inside of the frame to prevent air bypass and increase rigidity. 2.11.3.2 Extended Surface Nonsupported Pocket Filters
Provide [30][_____] inch depth, sectional, replaceable dry media type filters of the size indicated with a MERV of 13 when tested according to ASHRAE 52.2. Provide initial resistance at [500][_____] fpm that does not exceed [0.45][_____] inches water gauge. Provide UL Class 1 filters. Provide fibrous glass media, supported in the air stream by a wire or non-woven synthetic backing and secured to a galvanized steel metal header. Provide pockets that do not sag or flap at anticipated air flows. Install each filter [with an extended surface pleated panel filter as a prefilter] in a factory preassembled, side access housing or a factory-made sectional frame bank, as indicated. 2.10.3.2 Cartridge Type Filters
Provide 12 inch depth, sectional, replaceable dry media type filters of the size indicated with a MERV of 13 when tested according to ASHRAE 52.2. Provide initial resistance at [500][_____] fpm that does not exceed [0.56 ][_____] inches, water gauge. Provide UL class 1 filters, and pleated microglass paper media with corrugated aluminum separators, sealed inside the filter cell to form a totally rigid filter assembly. Fluctuations in filter face velocity or turbulent airflow have no effect on filter integrity or performance. Install each filter [with an extended surface pleated media panel filter as a prefilter] in a factory preassembled side access housing, or a factory-made sectional frame bank, as indicated. 2.11.3.4 Sectional Cleanable Filters
Provide [1][2] inch thick cleanable filters. Provide viscous adhesive in 5 gallon containers in sufficient quantity for 12 cleaning operations and not SECTION 23 00 00 Page 27
123044
less than one quart for each filter section. Provide one washing and charging tank for every 100 filter sections or fraction thereof; with each washing and charging unit consisting of a tank and [single][double] drain rack mounted on legs and drain rack with dividers and partitions to properly support the filters in the draining position. 2.11.3.5 Replaceable Media Filters
Provide the [dry-media][viscous adhesive] type replaceable media filters, of the size required to suit the application. Provide filtering media that is not less than 2 inches thick fibrous glass media pad supported by a structural wire grid or woven wire mesh. Enclose pad in a holding frame of not less than 16 gauge galvanized steel, equipped with quick-opening mechanism for changing filter media. Base the air flow capacity of the filter on net filter face velocity not exceeding [300][_____] fpm, with initial resistance of [0.13][_____] inches water gauge. Provide MERV that is not less than [_____] when tested according to ASHRAE 52.2. 2.11.3.6 Automatic Renewable Media Filters
Provide the following: a. Automatic, renewable media filters consisting of a horizontal or vertical traveling curtain of adhesive-coated bonded fibrous glass supplied in convenient roll form, and filter that does not require water supply, sewer connections, adhesive reservoir, or sprinkler equipment as part of the operation and maintenance requirements. Basic frame that is fabricated of not less than 14 gauge galvanized steel, and sectional design filters with each section of each filter fully factory assembled, requiring no field assembly other than setting in place next to any adjacent sections and the installation of media in roll form. Each filter complete with initial loading of filter media drive motor adequate to handle the number of sections involved, and [painted steel] [stainless steel] control box containing a warning light to indicate media runout, a runout switch, and a Hand-Off-Auto selector switch. Media feed across the filter face in [full-face increments] [increments] automatically controlled as determined by [filter pressure differential] [time interval control] [time interval control with pressure override] [photo electric control] to provide substantially constant operating resistance to airflow and varying not more than plus or minus 10 percent. Roll or enclose media in such a way that collected particulates can not re-entrain. Rolls of clean media, no less than 65 feet long, rerolled on disposable spools in the rewind section of the filter after the media has accumulated its design dirt load. Equip rewind section with a compression panel to tightly rewind used media for ease of handling. Media shall be of continuous, bonded fibrous glass material, UL Class 2, that does not compress more than 1/4 inch when subjected to air flow at 500 fpm. Factory charge media with an odorless and flame retardant adhesive which does not flow while in storage nor when subjected to temperatures up to 175 degrees F. Support media on both the leaving and entering air faces. Clean media shall have initial resistance that does not exceed 0.18 inch water gauge at its rated velocity of 500 fpm. Set control so that the resistance to air flow is between 0.40-and 0.50 SECTION 23 00 00 Page 28
b.
c.
d.
e.
123044
inch water gauge unless otherwise indicated. f. Dust holding capacity, of 80 percent average arrestance under these operating conditions, when operating at a steady state with an upper operating resistance of 0.50 inch water gauge, that is at least 592 (55) grams of ASHRAE Standard Test Dust per square foot of media area, when tested according to the dynamic testing provisions of ASHRAE 52.2. The horizontal type automatic renewable media filters, when used in conjunction with factory fabricated air handling units, that are dimensionally compatible with the connecting air handling units, and horizontal type filter housings with all exposed surfaces factory insulated internally with 1 inch, 1-1/2 pound density neoprene coated fibrous glass with thermal conductivity not greater than 0.27 Btu/hour/degree F/square foot/inch of thickness. Access doors for horizontal filters with double wall construction as specified for plenums and casings for field-fabricated units in paragraph DUCT SYSTEMS. Electrostatic Filters
g.
h.
2.11.3.7
Provide the following: a. The combination dry agglomerator/extended surface, nonsupported pocket electrostatic filters or the combination dry agglomerator/automatic renewable, media (roll) type electrostatic filters, as indicated (except as modified). Supply each dry agglomerator electrostatic air filter with the correct quantity of fully housed power packs and equip with silicon rectifiers, manual reset circuit breakers, low voltage safety cutout, relays for field wiring to remote indication of primary and secondary voltages, with lamps mounted in the cover to indicate these functions locally. Equip power pack enclosure with external mounting brackets, and low and high voltage terminals fully exposed with access cover removed for ease of installation. Furnish interlock safety switches for each access door and access panel that permits access to either side of the filter, so that the filter is de-energized in the event that a door or panel is opened. Ozone generation within the filter that does not exceed five parts per one hundred million parts of air. Locate high voltage insulators in a serviceable location outside the moving air stream or on the clean air side of the unit. Fully expose ionizer wire supports and furnish ionizer wires precut to size and with formed loops at each end to facilitate ionizer wire replacement. Agglomerator cell plates that allow proper air stream entrainment of agglomerates and prevent excessive residual dust build-up, with cells that are open at the top and bottom to prevent accumulation of agglomerates which settle by gravity. Where the dry agglomerator electrostatic filter is indicated to be the automatic renewable media type, provide a storage section that utilizes a horizontal or vertical traveling curtain of adhesive-coated bonded fibrous glass for dry agglomerator storage section service supplied in 65 foot lengths in convenient roll form. Otherwise, provide section construction and roll media characteristics as specified for automatic renewable media filters. Also a dry agglomerator/renewable media combination with an initial air flow resistance, after installation of clean media, that does not exceed 0.25 inch water gauge at 500 fpm face velocity. SECTION 23 00 00 Page 29
b.
c.
123044
d.
A MERV of the combination that is not less than 15 when tested according to ASHRAE 52.2 at an average operating resistance of 0.50 inch water gauge. Where the dry agglomerator electrostatic filter is indicated to be of the extended surface nonsupported pocket filter type, provide a storage section as specified for extended surface non-supported pocket filters, with sectional holding frames or side access housings as indicated. A dry agglomerator/extended surface nonsupported pocket filter section combination with initial air flow resistance, after installation of clean filters, that does not exceed 0.65 inch water gauge at 500 fpm face velocity, with a MERV of the combination not less than 16 when tested according to ASHRAE 52.2. Furnish front access filters with full height air distribution baffles and upper and lower mounting tracks to permit the baffles to be moved for agglomerator cell inspection and service. When used in conjunction with factory fabricated air handling units, supply side access housings which have dimensional compatibility. High-Efficiency Particulate Air (HEPA) Filters
e.
2.11.3.8
Provide HEPA filters that meet the requirements of IEST RP-CC-001 and are individually tested and certified to have an efficiency of not less than [95] [99.97] percent, and an initial resistance at [_____] fpm that does not exceed [_____] inches water gauge. Provide filters that are constructed by pleating a continuous sheet of filter medium into closely spaced pleats separated by corrugated aluminum or mineral-fiber inserts, strips of filter medium, or by honeycomb construction of the pleated filter medium. Provide interlocking, dovetailed, molded neoprene rubber gaskets of 5-10 durometer that are cemented to the perimeter of the [upstream] [downstream] face of the filter cell sides. Provide self-extinguishing rubber-base type adhesive or other materials conforming to fire hazard classification specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. Provide filter cell sides that are [ 3/4 inch thick exterior grade fire-retardant plywood] [cadmium plated steel] [galvanized steel] assembled in a rigid manner. Provide overall cell side dimensions that are correct to 1/16 inch, and squareness that is maintained to within 1/8 inch. Provide holding frames that use spring loaded fasteners or other devices to seal the filter tightly within it and that prevent any bypass leakage around the filter during its installed life. Provide air capacity and the nominal depth of the filter as indicated. Install each filter in a factory preassembled side access housing or a factory-made sectional supporting frame as indicated. Provide prefilters of the type, construction and efficiency indicated. 2.10.3.3 Holding Frames
Fabricate frames from not lighter than 16 gauge sheet steel with rust-inhibitor coating. Equip each holding frame with suitable filter holding devices. Provide gasketed holding frame seats. Make all joints airtight. 2.10.3.4 Filter Gauges
Provide dial type filter gauges, diaphragm actuated draft for all filter stations, including those filters which are furnished as integral parts of factory fabricated air handling units. Gauges shall be at least 3-7/8 inches in diameter, with white dials with black figures, and [graduations] [ SECTION 23 00 00 Page 30
123044
graduated in 0.01 inch of water,] with a minimum range of 1 inch of water beyond the specified final resistance for the filter bank on which each gauge is applied. Provide each gauge with a screw operated zero adjustment and two static pressure tips with integral compression fittings, two molded plastic vent valves, two 5 foot minimum lengths of 1/4 inch diameter [ aluminum] [vinyl] tubing, and all hardware and accessories for gauge mounting. 2.11 2.12.1 AIR HANDLING UNITS Field-Fabricated Air Handling Units
Provide built-up units as specified in paragraph DUCT SYSTEMS. Provide fans, coils spray-coil dehumidifiers, and air filters as specified in paragraph AIR SYSTEMS EQUIPMENT for types indicated. 2.11.1 Factory-Fabricated Air Handling Units
Provide [single-zone draw-through type][ or ][single-zone blow-through type][ or ][multizone blow-through type][blow-through double-deck type][blow-through triple deck type] units for outdoor locations with sloped roofs as indicated. Units shall include fans, coils, energy transfer wheel assemblies, airtight insulated casing with base rail, [ prefilters,] [secondary filter sections,][ and ][diffuser sections where indicated,] [air blender] adjustable V-belt drives, belt guards for externally mounted motors, access sections where indicated, [mixing box] [ combination sectional filter-mixing box,] [[pan][drysteam][spray type] humidifier,] vibration-isolators, and appurtenances required for specified operation. Provide vibration isolators as indicated. Physical dimensions of each air handling unit shall be suitable to fit space allotted to the unit with the capacity indicated. Provide air handling unit that is rated in accordance with AHRI 430 and AHRI certified for cooling. 2.11.1.1 Casings
Provide the following: a. [Casing sections [[single] [ 2 inch double] wall type] [as indicated], constructed of a minimum 18 gauge galvanized steel, or 18 gauge corrosion-resisting sheet steel conforming to ASTM A167, Type 304.][ Inner casing of double-wall units that are a minimum 20 gauge solid galvanized steel or corrosion-resisting sheet steel conforming to ASTM A167, Type 304.] Design and construct casing with an integral insulated structural galvanized steel frame and 8 inch high base rail such that exterior panels are non-load bearing. Individually removable exterior panels with standard tools. Removal shall not affect the structural integrity of the unit. Furnish casings with access sections, according to paragraph AIR HANDLING UNITS, inspection doors, and access doors, all capable of opening a minimum of 90 degrees, as indicated. Insulated, fully gasketed, double-wall type inspection and access doors, of a minimum 18 gauge outer and 20 gauge inner panels made of either galvanized steel or corrosion-resisting sheet steel conforming to ASTM A167, Type 304. Doors shall be rigid and provided with heavy duty hinges and latches. Inspection doors shall be a minimum 12 inches wide by 12 inches high. Access doors shall be a minimum 24 inches wide, the full height of the unit casing or a minimum of 6 foot, SECTION 23 00 00 Page 31
b.
c.
123044
whichever is less. [Install a minimum 8 by 8 inches sealed glass window suitable for the intended application, in all access doors.] d. Double-wall insulated type drain pan (thickness equal to exterior casing) constructed of 16 gauge [galvanized steel] [corrosion resisting sheet steel conforming to ASTM A167, Type 304], conforming to ASHRAE 62.1. Construct drain pans water tight, treated to prevent corrosion, and designed for positive condensate drainage. When 2 or more cooling coils are used, with one stacked above the other, condensate from the upper coils shall not flow across the face of lower coils. Provide intermediate drain pans or condensate collection channels and downspouts, as required to carry condensate to the unit drain pan out of the air stream and without moisture carryover. Construct drain pan to allow for easy visual inspection, including underneath the coil without removal of the coil and to allow complete and easy physical cleaning of the pan underneath the coil without removal of the coil. Coils shall be individually removable from the casing. Casing insulation that conforms to NFPA 90A. Single-wall casing sections handling conditioned air shall be insulated with not less than 1 inch thick, 1-1/2 pound density coated fibrous glass material having a thermal conductivity not greater than 0.23 Btu/hr-sf-F. Double-wall casing sections handling conditioned air shall be insulated with not less than 2 inches of the same insulation specified for single-wall casings. Foil-faced insulation is not an acceptable substitute for use with double wall casing. Double wall insulation shall be completely sealed by inner and outer panels. Provide perforated inner walls for fan sections. Factory applied fibrous glass insulation that conforms to ASTM C 1071, except that the minimum thickness and density requirements do not apply, and that meets the requirements of NFPA 90A. Make air handling unit casing insulation uniform over the entire casing. Foil-faced insulation is not an acceptable substitute for use on double-wall access doors and inspections doors [and casing sections]. Duct liner material, coating, and adhesive that conforms to fire-hazard requirements specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. Protect exposed insulation edges and joints where insulation panels are butted with a metal nosing strip or coat to meet erosion resistance requirements of ASTM C 1071. A latched and hinged inspection door, in the fan and coil sections. Plus additional inspection doors, access doors and access sections [_____][where indicated]. Heating and Cooling Coils
e.
f.
g.
h.
2.11.1.2
Provide coils as specified in paragraph AIR SYSTEMS EQUIPMENT. 2.11.1.3 Air Filters
Provide air filters as specified in paragraph AIR SYSTEMS EQUIPMENT for types and thickness indicated. 2.11.1.4 Fans
Provide the following: SECTION 23 00 00 Page 32
123044
a.
Fans that are double-inlet, centrifugal type with each fan in a separate scroll. Dynamically balance fans and shafts prior to installation into air handling unit, then after it has been installed in the air handling unit, statically and dynamically balance the entire fan assembly. Mount fan wheelss on steel shafts, accurately ground and finished. Mount fans on structural steel frames and vibrating isolaters. Fan bearings that are sealed against dust and dirt and are precision self-aligning ball or roller type, with L50 rated bearing life at not less than 200,000 hours as defined by ABMA 9 and ABMA 11. Bearings shall be permanently lubricated or lubricated type with lubrication fittings readily accessible at the drive side of the unit. Support bearings by structural shapes, or die formed sheet structural members, or support plates securely attached to the unit casing. Do not fasten bearings directly to the unit sheet metal casing. Furnish fans and scrolls with coating indicated. Fans that are driven by a unit-mounted, or a floor-mounted motor connected to fans by V-belt drive complete with belt guard for externally mounted motors. Furnish belt guards that are the three-sided enclosed type with solid or expanded metal face. Belt drives shall be designed for not less than a 1.3 service factor based on motor nameplate rating. [Motor sheaves that are variable pitch for 25 hp and below and fixed pitch above 25 hp as defined by AHRI Guideline D.] Where fixed sheaves are required, the use of variable pitch sheaves is allowed during air balance, but replace them with an appropriate fixed sheave after air balance is completed. Select variable pitch sheaves to drive the fan at a speed that produces the specified capacity when set at the approximate midpoint of the sheave adjustment. Furnish motors for V-belt drives with adjustable bases, and with [open][splashproof][ totally enclosed] enclosures. Motor starters of [manual][magnetic][across-the-line][ reduced-voltage-start] type with [general-purpose ][weather-resistant][watertight] enclosure. Select unit fan or fans to produce the required capacity at the fan static pressure with sound power level as indicated. Obtain the sound power level values according to AMCA 300, ASHRAE 68, or AHRI 260. Access Sections and Filter/Mixing Boxes
b.
c.
d.
e.
2.11.1.5
Provide access sections where indicated and furnish with access doors as shown. Construct access sections and filter/mixing boxes in a manner identical to the remainder of the unit casing and equip with access doors. Design mixing boxes to minimize air stratification and to promote thorough mixing of the air streams. 2.12.2.6 Diffuser Sections
Furnish diffuser sections between the discharge of all housed supply fans [and cooling coils of blow-through single zone units][ and ][filter sections of those units with high efficiency filters located immediately downstream of the air handling unit fan section]. Provide diffuser sections that are fabricated by the unit manufacturer in a manner identical to the remainder of the unit casing, designed to be airtight under positive SECTION 23 00 00 Page 33
123044
static pressures up to [8][_____] inches water gauge and with an access door on each side for inspection purposes. Provide a diffuser section that contains a perforated diffusion plate, fabricated of galvanized steel, Type 316 stainless steel, aluminum, or steel treated for corrosion with manufacturer's standard corrosion-resisting finish, and designed to accomplish uniform air flow across the down-stream [coil][filters] while reducing the higher fan outlet velocity to within plus or minus 5 percent of the required face velocity of the downstream component. 2.12 2.12.1 TERMINAL UNITS Room Fan-Coil Units
Provide base units that include galvanized coil casing, coil assembly drain pan [valve and piping package,] [outside air damper,] [wall intake box,] air filter, fans, motor, fan drive, motor switch, an enclosure for cabinet models and casing for concealed models, leveling devices integral with the unit for vertical type units, and sound power levels as indicated. Obtain sound power level data or values for these units according to test procedures based on AHRI 350. Sound power values apply to units provided with factory fabricated cabinet enclosures and standard grilles. Values obtained for the standard cabinet models are acceptable for concealed models without separate test provided there is no variation between models as to the coil configuration, blowers, motor speeds, or relative arrangement of parts. Provide automatic valves and controls as specified in paragraph SUPPLEMENTAL COMPONENTS/SERVICES, subparagraph CONTROLS. Fasten each unit securely to the building structure. Provide units with capacity indicated. Provide room fan-coil units that are certified as complying with AHRI 440, and meet the requirements of UL 1995. 2.12.1.1 Enclosures
Fabricate enclosures from not lighter than 18 gauge steel, reinforced and braced. Provide enclosures with front panels that are removable and have 1/4 inch closed cell insulation or 1/2 inch thick dual density foil faced fibrous glass insulation. Make the exposed side of a high density, erosion-proof material suitable for use in air streams with velocities up to 4,500 fpm. Provide a discharge grille that is [adjustable] [fixed] and that is of such design as to properly distribute air throughout the conditioned space. Plastic discharge and return grilles are acceptable provided the plastic material is certified by the manufacturer to be classified as flame resistant according to UL 94 and the material complies with the heat deflection criteria specified in UL 1995. Provide galvanized or factory finished ferrous metal surfaces with corrosion resistant enamel, and access doors or removable panels for piping and control compartments, plus easy access for filter replacement. Provide duct discharge collar for concealedceiling recessed ducted supply models. 2.12.1.2 Fans
Provide steel or aluminum, multiblade, centrifugal type fans. In lieu of metal, fans and scrolls could be of non-metallic materials of suitably reinforced compounds with smooth surfaces. Dynamically and statically balance the fans. Provide accessible assemblies for maintenance. Disassemble and re-assemble by means of mechanical fastening devices and not by epoxies or cements.
SECTION 23 00 00
Page 34
123044
2.12.1.3
Coils
Fabricate coils from not less than 3/8 inch outside diameter seamless copper tubing, with copper or aluminum fins mechanically bonded or soldered to the tubes. Provide coils with not less than 1/2 inch outside diameter flare or sweat connectors, accessory piping package with thermal connections suitable for connection to the type of control valve supplied, and manual air vent. Test coils hydrostatically at 300 psi or under water at 250 psi air pressure. Provide coils suitable for 200 psi working pressure. Make provisions for coil removal. 2.12.1.4 Drain Pans
Size and locate drain and drip pans to collect all water condensed on and dripping from any item within the unit enclosure or casing. Provide condensate drain pans designed for self-drainage to preclude the buildup of microbial slime and thermally insulated to prevent condensation and constructed of not lighter than 21 gauge type 304 stainless steel or noncorrosive ABS plastic. Provide insulation with a flame spread rating not over 25 without evidence of continued progressive combustion, a smoke developed rating no higher than 50, and of a waterproof type or coated with a waterproofing material. Design drain pans so as to allow no standing water and pitch to drain. Provide minimum 3/4 inch NPT or 5/8 inch OD drain connection in drain pan. Provide plastic or metal auxiliary drain pans to catch drips from control and piping packages, eliminating insulation of the packages; if metal, provide auxiliary pans that comply with the requirements specified above. Extend insulation at control and piping connections 1 inch minimum over the auxiliary drain pan. Provide drain pan float cut-out switch to shut down fan if pan floods. 2.13.1.5 Manually Operated Outside Air Dampers
Provide manually operated outside air dampers according to the arrangement indicated, and parallel airfoil type dampers of galvanized construction. Provide blades that rotate on stainless steel or nylon sleeve bearings. 2.12.1.5 Filters
Provide filters of the fiberglass disposable type, 1 inch thick, conforming to ASTM F 1040. Filters in each unit shall be removable without the use of tools. 2.12.1.6 Motors
Provide motors of the permanent split-capacitor type with built-in thermal overload protection, directly connected to unit fans. Provide motor switch with two or three speeds and off, manually operated, and mounted on an identified plate [inside the unit below or behind an access door][ or ][adjacent to the room thermostat][as indicated]. In lieu of the above fan speed control, a solid-state variable-speed controller having a minimum speed reduction of 50 percent is allowed. Provide motors with permanently-lubricated or oilable sleeve-type or combination ball and sleeve-type bearings with vibration isolating mountings suitable for continuous duty. Provide a motor power consumption, shown in watts, at the fan operating speed selected to meet the specified capacity that does not exceed the following values:
SECTION 23 00 00
Page 35
123044
Free Discharge Motors Unit Capacity (cfm) 200 300 400 600 800 1000 1200 Maximum Power Consumption (Watts) 115V 230V 277V 70 110 90 100 110 110 170 150 150 180 210 220 240 240 230 310 250 270 440 400 440
High Static Motors Unit Capacity (cfm) 200 300 400 600 800 1000 1200 2.13.2 Coil Induction Units Maximum Power Consumption (Watts) 145 145 210 320 320 530 530
Provide base unit that includes air plenums, air-discharge nozzles, air discharge grilles, recirculation grilles, water coil assembly, valve and piping package, condensate drain pan, and adjustable air-balancing dampers, plus an enclosure for cabinet models and casing for concealed models. Make each unit capable of producing not less than the capacity indicated without exceeding the indicated static pressure. Provide a sound power level as indicated with power level data or values for these units based on tests conducted according to ASA S12.51. Sound power values apply to units provided with factory fabricated cabinet enclosures and standard grilles. The values obtained for the standard cabinet models are acceptable for concealed models without separate tests, provided there is no variation between models as to coil configuration, air discharge nozzles, air balancing dampers, or relative arrangement of parts. Provide automatic valves and controls as specified in paragraph SUPPLEMENTAL COMPONENTS/SERVICES, subparagraph CONTROLS. Secure each unit to the building structure. Provide units with capacity indicated. 2.13.2.1 Enclosures
Fabricate enclosures from not lighter than 18 gauge steel, reinforced and braced. Provide a removable front panel of enclosure and insulate when required acoustically and to prevent condensation. Provide discharge grilles that are [adjustable][integrally stamped] and properly distribute air throughout the conditioned space. Plastic discharge and return grilles are not acceptable. Provide access doors for all piping and control compartments. 2.13.2.2 Air Plenums
Fabricate plenums from galvanized steel with interior acoustically baffled and lined with sound absorbing material to attenuate the sound power from the primary air supply to the room. Provide heat-resistant nozzles that are integral with or attached airtight to the plenum. Where coil induction SECTION 23 00 00 Page 36
123044
units are supplied with vertical runouts, furnish a streamlined, vaned, mitered elbow transition piece for connection between the unit and ductwork. Provide an adjustable air-balancing damper in each unit. 2.13.2.3 Coils
Fabricate coils from not less than 3/8 inch outside diameter seamless copper tubing, with copper or aluminum fins, mechanically bonded or soldered to the tubes. Furnish coil connections with not less than 1/2 inch outside diameter flare or sweat connectors, accessory piping package with terminal connections suitable for connection to the type of control valve supplied, and manual air vent. Test coils hydrostatically at 300 psi or under water at 250 psi air pressure and provide coils suitable for 200 psi working pressure. 2.13.2.4 Screens
Provide easily accessible lint screens or throwaway filters for each unit. 2.13.2.5 Drain Pan
Size and locate drain and drip pans to collect condensed water dripping from any item within the unit enclosure. Provide drain pans constructed of not lighter than 21 gauge steel, galvanized after fabrication, and thermally insulated to prevent condensation. Provide insulation that has a flame spread rating not over 25 without evidence of continued progressive combustion, a smoke developed rating no higher than 50, and that is a waterproof type or coated with a waterproofing material. In lieu of the above, drain pans constructed of die-formed 22 gauge steel are allowed, formed from a single sheet and galvanized after fabrication and insulated and coated as for the 21 gauge steel material or of die-formed 21 gauge type 304 stainless steel insulated as specified above. Pitch drain pans to drain. Provide drain connection when a condensate drain system is indicated. Make connection a minimum 3/4 inch NPT or 5/8 inch OD. 2.12.2 a. Variable Air Volume (VAV) and Dual Duct Terminal Units Provide VAV and dual duct terminal units that are the type, size, and capacity shown, mounted in the ceiling or wall cavity, plus units that are suitable for single or dual duct system applications. Provide actuators and controls as specified in paragraph SUPPLEMENTAL COMPONENTS/SERVICES, subparagraph CONTROLS. For each VAV terminal unit, provide a temperature sensor in the unit discharge ductwork. Provide unit enclosures that are constructed of galvanized steel not lighter than 22 gauge or aluminum sheet not lighter than 18 gauge. Provide single or multiple discharge outlets as required. Units with flow limiters are not acceptable. Provide unit air volume that is factory preset and readily field adjustable without special tools. [ Provide reheat coils as indicated.] Attach a flow chart to each unit. Base acoustic performance of the terminal units upon units tested according to AHRI 880 with the calculations prepared in accordance with AHRI 885. Provide sound power level as indicated. Show discharge sound power for minimum and [1-1/2 ][_____] inches water gauge inlet static pressure. Provide acoustical lining according to NFPA 90A.
b.
c.
SECTION 23 00 00
Page 37
123044
2.13.3.1
Constant Volume, Single Duct Terminal Units
Provide constant volume, single duct, terminal units that contain within the casing, a constant volume regulator. Provide volume regulators that control air delivery to within plus or minus 5 percent of specified air flow subjected to inlet pressure from 3/4 to 6 inch water gauge. 2.13.3.2 Variable Volume, Single Duct Terminal Units
Provide variable volume, single duct, terminal units with a calibrated air volume sensing device, air valve or damper, actuator, and accessory relays. Provide units that control air volume to within plus or minus 5 percent of each air set point volume as determined by the thermostat with variations in inlet pressures from 3/4 to 6 inch water gauge. Provide units with an internal resistance not exceeding 0.4 inch water gauge at maximum flow range. Provide external differential pressure taps separate from the control pressure taps for air flow measurement with a 0 to 1 inch water gauge range. 2.12.2.1 Variable Volume, Single Duct, Fan-Powered Terminal Units
Provide variable volume, single duct, fan-powered terminal units with a calibrated air volume sensing device, air valve or damper, actuator, fan and motor, and accessory relays. Provide units that control primary air volume to within plus or minus 5 percent of each air set point as determined by the thermostat with variations in inlet pressure from 3/4 to 6 inch water gauge. Provide unit fan that is centrifugal, direct-driven, double-inlet type with forward curved blades. Provide either single speed with speed controller or three-speed, permanently lubricated, permanent split-capacitor type fan motor. Isolate fan/motor assembly from the casing to minimize vibration transmission. Provide factory furnished fan control that is wired into the unit control system. Provide a factory-mounted pressure switch to operate the unit fan whenever pressure exists at the unit primary air inlet or when the control system fan operates. 2.13.3.4 Dual Duct Terminal Units
Provide dual duct terminal units with hot and cold inlet valve or dampers that are controlled in unison by single or dual actuators. Provide actuator as specified in paragraph SUPPLEMENTAL COMPONENTS/SERVICES, subparagraph CONTROLS. Provide unit that controls delivered air volumes within plus or minus 5 percent with inlet air variations from 1 to 8 inch water gauge in either duct. Include mixing baffles with the unit casing. Provide cabinet and closed duct leakage that does not exceed 2 percent of maximum rated air volume. Provide units with an internal resistance that does not exceed [_____] inch water gauge at maximum flow range. 2.13.3.5 Ceiling Induction Terminal Units
Provide ceiling induction unit with a calibrated primary air volume sensing device, primary air valve, induced air damper, and insulated induction tube. Arrange unit to induce air from the ceiling plenum to maintain a maximum total flow circulated to the conditioned space. Vary primary air upon demand of the room thermostat. Upon a demand for maximum cooling, provide a unit that delivers 100 percent primary air and, at minimum cooling, delivers [50] [25] percent primary air. Provide a terminal unit capable of closing to full shut off without additional actuators or linkage changes. Provide terminals that reset primary air volume within plus or minus 5 percent determined by the thermostat regardless of upstream changes SECTION 23 00 00 Page 38
123044
in the static pressure. Provide a minimum inlet static pressure that does not exceed 1 inch water gauge, including a maximum of 0.3 inch water gauge downstream static pressure. Provide external differential pressure taps separate from control pressure taps for primary air flow measurement with 0 to 1 inch water gauge range. Make each unit normally [open] [closed] upon loss of pneumatic pressure. Factory pipe actuator and accuracy controls requiring only field installation of 20 psi pneumatic main air and room thermostat. 2.12.2.2 Series Fan Powered Variable Air Volume (VAV) Terminals
Provide units factory assembled, designed, and tested, rated in accordance with AHRI 880, that are AHRI certified, listed in the AHRI DCAACP the drawing schedules and that produce a supply air discharge mix by modulation of conditioned primary air and recirculating of return air. Provide units that include casing, centrifugal fan and motor, primary VAV damper or valve, electronic volume regulator, discharge air damper, primary air inlet cone with high and low pressure flow sensors, recirculating air filter frames, filter, and electrical disconnect. [Provide hot water heating coils integral to the terminal, or provide insulated hot water coil section attached to the discharge of the terminal.] a. Casing: Provide removable full bottom access panelsaccess on sides and top for servicing internal components without disturbing duct connections. Insulate inside of casing with manufacturer's standard insulation. Provide units that have recirculating air inlet equipped with filter frame, round primary damper or valve, and unit mounting brackets. Fans and motors: Provide centrifugal, forward curved, multiblade, fan wheels with direct-drive motors. Provide motors that are the high efficiency permanent-split capacitor type with thermal overload protection, permanently lubricated bearings, and have three speeds or are equipped with solid state speed controllers. Provide isolation between fan motor assembly and unit casing. Provide fan and motor that is removable through casing access panel. Flow sensor: Provide ring or cross type sensor with minimum of two pickup points which average the velocity across the inlet. Obtain flow measurement within plus or minus 5 percent of rated airflow with 1.5 diameters of straight duct upstream of unit and inlet static variation of 0.5 to 5.0 inches water gauge. Supply flow measuring taps and calibration flowchart with each unit for field balancing airflows. Primary VAV damper or valve: Provide galvanized steel damper blade that closes against gasket inside unit. Connect damper to operating shaft with a positive mechanical connection. Provide nylon bearing for damper shaft. Cylindrical die cast aluminum vValve inlet tapered to fit round flexible ducts with integral flow diffuser and beveled self-centering disc. Provide damper or valve leakage at shutoff that does not exceed 2 percent of capacity at 1 inch water gauge pressure. Regulator: Provide electronic volume regulator. Electronic controls contained in NEMA ICS 6, Type 1 enclosure sealed from airflow. Provide unit with controls mounted on side or on air valve. System powered regulators are not permitted. Provide volume regulator that resets primary air volume as determined by thermostat, within upstream static pressure variation noted in paragraph titled "Flow Sensor." Volume regulators shall be field adjustable, factory set and calibrated to SECTION 23 00 00 Page 39
b.
c.
d.
e.
123044
indicated maximum and minimum primary airflows, direct acting and normally [open] [closed] upon loss of pneumatic pressure. f. Electrical: Provide unit that incorporates single point electrical connection with electrical disconnect. Electrical components shall be UL or ETL listed, installed in accordance with NFPA 70 and mounted in control box. Units UL or ETL listed as an assembly do not require airflow switch interlock with electric heating coil, when factory assembled. Filters: Provide UL listed throwaway one inch thick fiberglass filters, standard dust-holding capacity. Reheat Units Hot Water Coils: Provide fin-and-tube type hot-water coils constructed of seamless copper tubes and copper or aluminum fins mechanically bonded or soldered to the tubes. Provide headers that are constructed of cast iron, welded steel or copper. Provide casing and tube support sheets that are 16 gauge, galvanized steel, formed to provide structural strength. Provide tubes that are correctly circuited for proper water velocity without excessive pressure drop and are drainable where required or indicated. At the factory, test each coil at not less than 250 psi air pressure and provide coils suitable for 200 psi working pressure. Install drainable coils in the air handling units with a pitch of not less than 1/8 inch per foot of tube length toward the drain end. Coils shall conform to the provisions of AHRI 410. Steam Coils: Provide steam coils constructed of cast semisteel, welded steel, or copper headers, red-brass or copper tubes, and copper or aluminum fins mechanically bonded or soldered to the tubes. Roll and bush, braze or weld tubes into headers. Provide coil casings and tube support sheets, with collars of ample width, that are not lighter than 16 gauge galvanized steel formed to provide structural strength. When required, furnish multiple tube supports to prevent tube sag. Float the fin tube and header section within the casing to allow free expansion of tubing for coils subject to high pressure steam service. Provide coils that are factory pressure tested and capable of withstanding 250 psi hydrostatic test pressure or 250 psi air pressure, and are for [100] [200] psi steam working pressure. Provide steam-distribution tube type preheat coils with condensing tubes having not less than 5/8 inch outside diameters. Provide distribution tubes that have not less than 3/8 inch outside diameter, with orifices to discharge steam to condensing tubes. Install distribution tubes concentric inside of condensing tubes held securely in alignment. Limit the maximum length of a single coil to 120 times the diameter of the outside tube. Other heating coils shall be single tube type with not less than 1/2 inch outside diameter. Provide supply headers that distribute steam evenly to all tubes at the indicated steam pressure. Coils shall conform to the provisions of AHRI 410. Electric Resistance Heaters: Provide the duct-mounting type electric resistance heaters consisting of a nickel-chromium resistor mounted on refractory material and a steel or aluminum frame for attachment to ductwork. Provide electric duct heater that meets the requirement of Underwriters Laboratories and NFPA 70 SECTION 23 00 00 Page 40
g.
2.12.2.3 a.
b.
c.
123044
and is provided with a built-in or surface-mounted high-limit thermostat. Interlock electric duct heaters electrically so that they cannot be energized unless the fan is running. 2.13.4 Unit Ventilators
Provide unit ventilators that include an enclosure, [galvanized casing,] [cold-rolled steel casing with corrosion resistant coating,] coil assembly, [resistance heating coil assembly,] [valve and piping package,] drain pan, air filters, fan assembly, fan drive, motor, motor controller, dampers, damper operators, and sound power level as indicated. Obtain sound power level data or values for these units according to test procedures based on AHRI 350. Sound power values apply to units provided with factory fabricated cabinet enclosures and standard grilles, when handling standard flow for which the unit air capacity is rated. Secure each unit to the building structure. Provide the unit ventilators with capacity indicated. Provide the year-round classroom type unit ventilator with automatic controls arranged to properly heat, cool, and ventilate the room. Provide automatic valves and controls as specified in paragraph SUPPLEMENTAL COMPONENTS/SERVICES, subparagraph CONTROLS. Make the sequence of control any one of the standard ANSI cycles specified in paragraph CONTROLS. 2.13.4.1 Enclosures
Fabricate enclosures from not lighter than 16 gauge galvanized steel, reinforced and braced, or all welded framework with panels to provide equivalent strength. Provide casing that is acoustically and thermally insulated internally with not less than 1/2 inch thick dual density fibrous glass insulation. Make the exposed side a high density, erosion-proof material suitable for use in air streams with velocities up to 4500 fpm. Fasten the insulation with waterproof, fire-resistant adhesive. Design front panel for easy removal by one person. Provide discharge grilles that [have adjustable grilles or grilles with adjustable vanes and] properly distribute air throughout the conditioned space. Provide return grilles that are removable where front panel does not provide access to interior components. Plastic discharge or return grilles are not acceptable. Furnish removable panels or access doors for all piping and control compartments. Provide fan switch that is key operated or accessible through a locked access panel. Install gaskets at the back and bottom of the unit for effective air seal, as required. 2.13.4.2 Electric Resistance Heating Elements
Provide electric resistance heating elements that are of the sheathed, finned, tubular type, or of the open resistance type designed for direct exposure to the air stream. Provide heating element electrical characteristics as indicated. Where fan motor or control voltage is lower than required for the electric-resistance heating element, install a fused factory mounted and wired transformer. 2.13.4.3 Fans
Provide fans that meet the requirements of ASHRAE 90.1 - IP as specified in paragraph AIR SYSTEMS EQUIPMENT. Provide galvanized steel or aluminum, multiblade, centrifugal type fans, dynamically and statically balanced. Equip fan housings with resilient mounted, self-aligning permanently lubricated ball bearings, sleeve bearings, or combination ball and sleeve bearings, capable of not less than 2000 hours of operation on one oiling. Provide direct-connected fans. SECTION 23 00 00 Page 41
123044
2.13.4.4
Coils
Provide coils that are circuited for a maximum water velocity of 8 fps without excessive pressure drop and are otherwise as specified for hot water coils in paragraph TERMINAL UNITS. 2.13.4.5 Drain Pans
Size and locate drain and drip pans to collect all condensed water dripping from any item within the unit enclosure. Provide drain pans constructed of not lighter than 18 gauge steel, galvanized after fabrication, and thermally insulated to prevent condensation. Provide insulation that is coated with a fire-resistant waterproofing material. In lieu of the above, drain pans constructed of die-formed 20 gauge steel is allowed, formed from a single sheet and galvanized after fabrication and insulated and coated as for the 18 gauge steel material, or of die-formed 18 gauge type 304 stainless steel insulated as specified above. Pitch drain pans to drain. Furnish drain connection unless otherwise indicated. Make the minimum connection 3/4 inch NDT or 5/8 inch OD. 2.13.4.6 Filters
Fiberglass disposable type, 1 inch thick, rated in accordance with ASTM F 1040, installed upstream of coil. 2.13.4.7 Dampers
Provide an outside air proportioning damper on each unit. In addition, provide a vane to prevent excessive outside air from entering unit and to prevent blow-through of outside air through the return air grille under high wind pressures. Where outside air and recirculated air proportioning dampers are provided on the unit, an additional vane is not required. Provide face and bypass dampers for each unit to ensure constant air volume at all positions of the dampers. Furnish each unit with a factory installed control cam assembly, pneumatic motor, or electric motor to operate the face and bypass dampers and outside air damper or outside air and recirculated air dampers in the sequence as specified in paragraph SUPPLEMENTAL COMPONENTS/SERVICES, subparagraph CONTROLS. 2.13.4.8 Motors
Provide permanent split-capacitor type motors with built-in thermal overload protection and automatic reset. Mount motor on a resilient mounting, isolated from the casing and suitable for operation on electric service available. Provide a manually operated motor switch that provides for 2 or 3 speeds and off, mounted on an identified plate [inside the unit below or behind an access door][ or ][adjacent to the room thermostat][as indicated]. In lieu of speed control, provide a solid state variable speed controller having minimum speed reduction of 50 percent. 2.13.4.9 Outside Air Intakes
Provide the manufacturer's standard design outside air intakes furnished with 1/2 inch mesh bird screen or louvers on 1/2 inch centers.
SECTION 23 00 00
Page 42
123044
2.13 2.14.1
ENERGY RECOVERY DEVICES Rotary Wheel
Provide unit that is a factory fabricated and tested assembly for air-to-air energy recovery by transfer of sensible heat from exhaust air to supply air stream, with device performance according to ASHRAE 84 and that delivers an energy transfer effectiveness of not less than [70][85][_____] percent with cross-contamination not in excess of [0.1][1.0][_____] percent of exhaust airflow rate at system design differential pressure, including purging sector if provided with wheel. Provide exchange media that is chemically inert, moisture-resistant, fire-retardant, laminated, nonmetallic material which complies with NFPA 90A. Isolate exhaust and supply streams by seals which are static, field adjustable, and replaceable. Equip chain drive mechanisms with ratcheting torque limiter or slip-clutch protective device. Fabricate enclosure from galvanized steel and include provisions for maintenance access. Provide recovery control and rotation failure provisions as indicated. 2.14.2 Run-Around-Coil
Provide assembly that is factory fabricated and tested air-to-liquid-to-air energy recovery system for transfer of sensible heat from exhaust air to supply air stream and that delivers an energy transfer effectiveness not less than that indicated without cross-contamination with maximum energy recovery at minimum life cycle cost. Computer optimize components for capacity, effectiveness, number of coil fins per inch, number of coil rows, flow rate, heat transfer rate of [_____] percent by volume of [ethylene][propylene] glycol solution, and frost control. Provide coils that conform to paragraph AIR HANDLING UNITS. Provide related pumps, and piping specialties that conform to requirements of [Section 23 63 00.00 10 COLD STORAGE REFRIGERATION SYSTEMS][Section 23 57 10.00 10 FORCED HOT WATER HEATING SYSTEMS USING WATER AND STEAM HEAT EXCHANGERS][23 69 00.00 20 REFRIGERATION EQUIPMENT FOR COLD STORAGE] [_____]. 2.14.3 Heat Pipe
Provide a device that is a factory fabricated, assembled and tested, counterflow arrangement, air-to-air heat exchanger for transfer of sensible heat between exhaust and supply streams and that delivers an energy transfer effectiveness not less than that indicated without cross-contamination. Provide heat exchanger tube core that is [1/2][5/8][1] inch nominal diameter, seamless aluminum or copper tube with extended surfaces, utilizing wrought aluminum Alloy 3003 or Alloy 5052, temper to suit. Provide maximum fins per unit length and number of tube rows as indicated. Provide tubes that are fitted with internal capillary wick, filled with an ANSI/ASHRAE 15 & 34, Group 1 refrigerant working fluid, selected for system design temperature range, and hermetically sealed. Provide heat exchanger frame that is constructed of not less than 16 gauge galvanized steel and fitted with intermediate tube supports, and flange connections. Provide tube end-covers and a partition of galvanized steel to separate exhaust and supply air streams without cross-contamination and in required area ratio.[ Provide a drain pan constructed of welded Type 300 series stainless steel.] Provide heat recovery regulation by [system face and bypass dampers and related control system as indicated][interfacing with manufacturer's standard tilt-control mechanism for summer/winter operation, regulating the supply air temperature and frost prevention on weather face of exhaust side at temperature indicated]. Coil shall be fitted with pleated flexible SECTION 23 00 00 Page 43
123044
connectors. 2.13.1 Desiccant Wheel
Provide counterflow supply, regeneration airstreams, a rotary type dehumidifier designed for continuous operation, and extended surface type wheel structure in the axial flow direction with a geometry that allows for laminar flow over the operating range for minimum air pressure differentials. Provide the dehumidifier complete with a drive system utilizing a fractional-horsepower electric motor and speed reducer assembly driving the rotor. Include a slack-side tensioner for automatic take-up for belt-driven wheels. Provide an adsorbing type desiccant material. Apply the desiccant material to the wheel such that the entire surface is active as a desiccant and the desiccant material does not degrade or detach from the surface of the wheel which is fitted with full-face, low-friction contact seals on both sides to prevent cross leakage. Provide rotary structure that has underheat, overheat and rotation fault circuitry. The wheel assembly shall come with a warranty for a minimum of five years. 2.14.5 Plate Heat Exchanger
Provide energy recovery ventilator unit that is factory-fabricated for indoor installation, consisting of a flat plate cross-flow heat exchanger, cooling coil, supply air fan and motor and exhaust air fan and motor. The casing shall be 20 gauge G90, galvanized steel, double wall construction with one inch insulation. Provide fibrous desiccant cross-flow type heat exchanger core capable of easy removal from the unit. 2.14 FACTORY PAINTING
Factory paint new equipment, which are not of galvanized construction. Paint with a corrosion resisting paint finish according to ASTM A123/A123M or ASTM A924/A924M. Clean, phosphatize and coat internal and external ferrous metal surfaces with a paint finish which has been tested according to ASTM B 117, ASTM D 1654, and ASTM D 3359. Submit evidence of satisfactory paint performance for a minimum of 125 hours for units to be installed indoors and 500 hours for units to be installed outdoors. Provide rating of failure at the scribe mark that is not less than 6, average creepage not greater than 1/8 inch. Provide rating of the inscribed area that is not less than 10, no failure. On units constructed of galvanized steel that have been welded, provide a final shop docket of zinc-rich protective paint on exterior surfaces of welds or welds that have burned through from the interior according to ASTM D 520 Type I. Factory painting that has been damaged prior to acceptance by the Contracting Officer shall be field painted in compliance with the requirements of paragraph FIELD PAINTING OF MECHANICAL EQUIPMENT. 2.15 2.15.1 SUPPLEMENTAL COMPONENTS/SERVICES Chilled, Condenser, or Dual Service Water Piping
The requirements for chilled, condenser, or dual service water piping and accessories are specified in Section 23 64 26 CHILLED, CHILLED-HOT, AND CONDENSER WATER PIPING SYSTEMS 2.16.2 Refrigerant Piping
The requirements for refrigerant piping are specified in Section 23 23 00 SECTION 23 00 00 Page 44
123044
REFRIGERANT PIPING. 2.15.2 Water or Steam Heating System Accessories
The requirements for water or steam heating accessories such as expansion tanks and steam traps are specified in Section [23 52 43.00 2000 HEATING BOILERSLOW TEMPERATURE WATER (LTW) HEATING SYSTEM][23 21 13.00 20 LOW TEMPERATURE WATER (LTW) HEATING SYSTEM][23 22 26.00 20 STEAM SYSTEM AND TERMINAL UNITS]. 2.15.3 Condensate Drain Lines
Provide and install condensate drainage for each item of equipment that generates condensate in accordance with Section [22 00 00 PLUMBING, GENERAL PURPOSE][23 64 26 CHILLED, CHILLED-HOT, AND CONDENSER WATER PIPING SYSTEMS] except as modified herein. 2.15.4 Backflow Preventers
The requirements for backflow preventers are specified in Section 22 00 00 PLUMBING, GENERAL PURPOSE. 2.15.5 Insulation
The requirements for shop and field applied insulation are specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. 2.15.6 Controls
The requirements for controls are specified in [Section 23 05 93 TESTING, ADJUSTING, AND BALANCING OF HVAC SYSTEMS][ and ][Section 23 09 23 LONWORKS DIRECT DIGITAL CONTROL FOR HVAC AND OTHER LOCAL BUILDING SYSTEMS][Section 23 09 53.00 20 SPACE TEMPERATURE CONTROL SYSTEMS][ and ][23 09 23.13.22 BACnet DIRECT DIGITAL CONTROL SYSTEMS FOR HVAC]. PART 3 3.1 EXECUTION EXAMINATION
After becoming familiar with all details of the work, verify all dimensions in the field, and advise the Contracting Officer of any discrepancy before performing the work. 3.2 a. INSTALLATION Install materials and equipment in accordance with the requirements of the contract drawings and approved manufacturer's installation instructions. Accomplish installation by workers skilled in this type of work. Perform installation so that there is no degradation of the designed fire ratings of walls, partitions, ceilings, and floors. No installation is permitted to block or otherwise impede access to any existing machine or system. Install all hinged doors to swing open a minimum of 120 degrees. Provide an area in front of all access doors that clears a minimum of [3][_____] feet. In front of all access doors to electrical circuits, clear the area the minimum distance to energized circuits as specified in OSHA Standards, part 1910.333 (Electrical-Safety Related work practices)and an additional [3][_____] feet. SECTION 23 00 00 Page 45
b.
123044
c.
Except as otherwise indicated, install emergency switches and alarms in conspicuous locations. Mount all indicators, to include gauges, meters, and alarms in order to be easily visible by people in the area. Condensate Drain Lines
3.2.1
Provide water seals in the condensate drain from all [units] [units except room [fan-coil units][ and ][coil-induction units]]. Provide a depth of each seal of 2 inches plus the number of inches, measured in water gauge, of the total static pressure rating of the unit to which the drain is connected. Provide water seals that are constructed of 2 tees and an appropriate U-bend with the open end of each tee plugged. Provide pipe cap or plug cleanouts where indicated. Connect drains indicated to connect to the sanitary waste system using an indirect waste fitting. Insulate air conditioner drain lines as specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. 3.2.2 Equipment and Installation
Provide frames and supports for tanks, compressors, pumps, valves, air handling units, fans, coils, dampers, ductwork and piping located outdoors,andand other similar items requiring supports.Mount vertical duct work and pipe supports on concrete bases suitable for systems supported. Floor mount or ceiling huang air handling units as indicated. Anchor and fasten as detailed. Set floor-mounted equipment on not less than 6 inch concrete pads or curbs doweled in place unless otherwise indicated. Make concrete foundations heavy enough to minimize the intensity of the vibrations transmitted to the piping, duct work and the surrounding structure, as recommended in writing by the equipment manufacturer. In lieu of a concrete pad foundation, build a concrete pedestal block with isolators placed between the pedestal block and the floor. Make the concrete foundation or concrete pedestal block a mass not less than three times the weight of the components to be supported. Provide the lines connected to the pump mounted on pedestal blocks with flexible connectors. Submit foundation drawings as specified in paragraph DETAIL DRAWINGS. Provide concrete for foundations as specified in Section [03 30 00.00 10 CAST-IN-PLACE CONCRETE] [03 30 00 CAST-IN-PLACE CONCRETE]. 3.2.3 Access Panels
Install access panels for concealed valves, vents, controls, dampers, and items requiring inspection or maintenance of sufficient size, and locate them so that the concealed items are easily serviced and maintained or completely removed and replaced. Provide access panels as specified in Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS. 3.2.4 Flexible Duct
Install pre-insulated flexible duct in accordance with the latest printed instructions of the manufacturer to ensure a vapor tight joint. Provide hangers, when required to suspend the duct, of the type recommended by the duct manufacturer and set at the intervals recommended. 3.2.5 Metal Ductwork
Install according to SMACNA 1966 unless otherwise indicated. Install duct supports for sheet metal ductwork according to SMACNA 1966, unless otherwise specified. Do not use friction beam clamps indicated in SECTION 23 00 00 Page 46
123044
SMACNA 1966. Anchor risers on high velocity ducts in the center of the vertical run to allow ends of riser to move due to thermal expansion. Erect supports on the risers that allow free vertical movement of the duct. Attach supports only to structural framing members and concrete slabs. Do not anchor supports to metal decking unless a means is provided and approved for preventing the anchor from puncturing the metal decking. Where supports are required between structural framing members, provide suitable intermediate metal framing. Where C-clamps are used, provide retainer clips. 3.2.5.1 Underground Ductwork
Provide PVC plastisol coated galvanized steel underground ductwork with coating on interior and exterior surfaces and watertight joints. Install ductwork as indicated, according to ACCA Manual 4 and manufacturer's instructions. Maximum burial depth is 6 feet. 3.2.5.2 Radon Exhaust Ductwork Install PVC joints as
Perforate subslab suction piping where indicated. specified in ASTM D 2855. 3.2.5.3 Light Duty Corrosive Exhaust Ductwork
For light duty corrosive exhaust ductwork, use PVC plastisol coated galvanized steel with PVC coating on interior [surfaces][ and exterior surfaces][ and epoxy wash primer coating on exterior surfaces]. 3.2.6 FRP Ductwork related structures where indicated. flanged joints are not 50 degrees F, heat
Provide fibrous glass reinforced plastic ducting and that conform to SMACNA 1403. Provide flanged joints Crevice-free butt lay-up joints are acceptable where indicated. When ambient temperatures are lower than cure joints by exothermic reaction heat packs. 3.2.7 3.2.7.1 Kitchen Exhaust Ductwork
Ducts Conveying Smoke and Grease Laden Vapors
Provide ducts conveying smoke and grease laden vapors that conform to requirements of NFPA 96. Make seams, joints, penetrations, and duct-to-hood collar connections with a liquid tight continuous external weld. Provide duct material that is a [minimum 18 gauge, Type 304L or 316L, stainless steel] [minimum 16 gauge carbon steel]. [Include with duct construction an external perimeter angle sized in accordance with SMACNA 1966, except place welded joint reinforcement on maximum of 24 inch centers; continuously welded companion angle bolted flanged joints with flexible ceramic cloth gaskets where indicated; pitched to drain at low points; welded pipe coupling-plug drains at low points; welded fire protection and detergent cleaning penetration; steel framed, stud bolted, and flexible ceramic cloth gasketed cleaning access provisions where indicated. Make angles, pipe couplings, frames, bolts, etc., the same material as that specified for the duct unless indicated otherwise.] 3.2.7.2 Exposed Ductwork
Provide exposed ductwork that is fabricated from minimum 18 gauge, Type 304L or 316L, stainless steel with continuously welded joints and seams. SECTION 23 00 00 Page 47
123044
Pitch ducts to drain at hoods and low points indicated. finish to hoods. 3.2.7.3 Concealed Ducts Conveying Moisture Laden Air
Match surface
Fabricate concealed ducts conveying moisture laden air from minimum [ 18 gauge, Type 300 series, stainless steel] [ 16 gauge, galvanized steel] [ 16 ounce, tempered copper sheet]. Continuously weld, braze, or solder joints to be liquid tight. Pitch ducts to drain at points indicated. Make transitions to other metals liquid tight, companion angle bolted and gasketed. 3.2.8 Acoustical Duct Lining
Apply lining in cut-to-size pieces attached to the interior of the duct with nonflammable fire resistant adhesive conforming to ASTM C 916, Type I, NFPA 90A, UL 723, and ASTM E 84. Provide top and bottom pieces that lap the side pieces and are secured with welded pins, adhered clips of metal, nylon, or high impact plastic, and speed washers or welding cup-head pins installed according to SMACNA 1966. Provide welded pins, cup-head pins, or adhered clips that do not distort the duct, burn through, nor mar the finish or the surface of the duct. Make pins and washers flush with the surfaces of the duct liner and seal all breaks and punctures of the duct liner coating with the nonflammable, fire resistant adhesive. Coat exposed edges of the liner at the duct ends and at other joints where the lining is subject to erosion with a heavy brush coat of the nonflammable, fire resistant adhesive, to prevent delamination of glass fibers. Apply duct liner to flat sheet metal prior to forming duct through the sheet metal brake. Additionally secure lining at the top and bottom surfaces of the duct by welded pins or adhered clips as specified for cut-to-size pieces. Other methods indicated in SMACNA 1966 to obtain proper installation of duct liners in sheet metal ducts, including adhesives and fasteners, are acceptable. 3.2.6 Dust Control
To prevent the accumulation of dust, debris and foreign material during construction, perform temporary dust control protection. Protect the distribution system (supply and return) with temporary seal-offs at all inlets and outlets at the end of each day's work. Keep temporary protection in place until system is ready for startup. 3.2.7 Insulation
Provide thickness and application of insulation materials for ductwork, piping, and equipment according to Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. Externally insulate outdoor air intake ducts and plenums [up to the point where the outdoor air reaches the conditioning unit ][ or ][up to the point where the outdoor air mixes with the outside air stream]. 3.2.8 Duct Test Holes
Provide holes with closures or threaded holes with plugs in ducts and plenums as indicated or where necessary for the use of pitot tube in balancing the air system. Plug insulated duct at the duct surface, patched over with insulation and then marked to indicate location of test hole if needed for future use.
SECTION 23 00 00
Page 48
123044
3.2.12
Power Roof Ventilator Mounting
Provide foamed 1/2 inch thick, closed-cell, flexible elastomer insulation to cover width of roof curb mounting flange. Where wood nailers are used, predrill holes for fasteners. 3.2.9 Power Transmission Components Adjustment
Test V-belts and sheaves for proper alignment and tension prior to operation and after 72 hours of operation at final speed. Uniformly load belts on drive side to prevent bouncing. Make alignment of direct driven couplings to within 50 percent of manufacturer's maximum allowable range of misalignment. 3.3 EQUIPMENT PADS
Provide equipment pads to the dimensions shown or, if not shown, to conform to the shape of each piece of equipment served with a minimum 3-inch margin around the equipment and supports. Allow equipment bases and foundations, when constructed of concrete or grout, to cure a minimum of [28][14][_____] calendar days before being loaded. 3.4 CUTTING AND PATCHING
Install work in such a manner and at such time that a minimum of cutting and patching of the building structure is required. Make holes in exposed locations, in or through existing floors, by drilling and smooth by sanding. Use of a jackhammer is permitted only where specifically approved. Make holes through masonry walls to accommodate sleeves with an iron pipe masonry core saw. 3.5 CLEANING
Thoroughly clean surfaces of piping and equipment that have become covered with dirt, plaster, or other material during handling and construction before such surfaces are prepared for final finish painting or are enclosed within the building structure. Before final acceptance, clean mechanical equipment, including piping, ducting, and fixtures, and free from dirt, grease, and finger marks. When the work area is in an occupied space such as office, laboratory or warehouse [_____] protect all furniture and equipment from dirt and debris. Incorporate housekeeping for field construction work which leaves all furniture and equipment in the affected area free of construction generated dust and debris; and, all floor surfaces vacuum-swept clean. 3.6 PENETRATIONS
Provide sleeves and prepared openings for duct mains, branches, and other penetrating items, and install during the construction of the surface to be penetrated. Cut sleeves flush with each surface. Place sleeves for round duct 15 inches and smaller. Build framed, prepared openings for round duct larger than 15 inches and square, rectangular or oval ducts. Sleeves and framed openings are also required where grilles, registers, and diffusers are installed at the openings. Provide one inch clearance between penetrating and penetrated surfaces except at grilles, registers, and diffusers. Pack spaces between sleeve or opening and duct or duct insulation with mineral fiber conforming with ASTM C 553, Type 1, Class B-2. a. Sleeves: Fabricate sleeves, except as otherwise specified or indicated, SECTION 23 00 00 Page 49
123044
from 20 gauge thick mill galvanized sheet metal. Where sleeves are installed in bearing walls or partitions, provide black steel pipe conforming with ASTM A53/A53M, Schedule 20. b. Framed Prepared Openings: Fabricate framed prepared openings from 20 gauge galvanized steel, unless otherwise indicated. Insulation: Provide duct insulation in accordance with Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS continuous through sleeves and prepared openings except firewall penetrations. Terminate duct insulation at fire dampers and flexible connections. For duct handling air at or below 60 degrees F, provide insulation continuous over the damper collar and retaining angle of fire dampers, which are exposed to unconditioned air. Closure Collars: Provide closure collars of a minimum 4 inches wide, unless otherwise indicated, for exposed ducts and items on each side of penetrated surface, except where equipment is installed. Install collar tight against the surface and fit snugly around the duct or insulation. Grind sharp edges smooth to prevent damage to penetrating surface. Fabricate collars for round ducts 15 inches in diameter or less from 20 gauge galvanized steel. Fabricate collars for square and rectangular ducts, or round ducts with minimum dimension over 15 inches from 18 gauge galvanized steel. Fabricate collars for square and rectangular ducts with a maximum side of 15 inches or less from 20 gauge galvanized steel. Install collars with fasteners a maximum of 6 inches on center. Attach to collars a minimum of 4 fasteners where the opening is 12 inches in diameter or less, and a minimum of 8 fasteners where the opening is 20 inches in diameter or less. Firestopping: Where ducts pass through fire-rated walls, fire partitions, and fire rated chase walls, seal the penetration with fire stopping materials as specified in Section 07 84 00 FIRESTOPPING. FIELD PAINTING OF MECHANICAL EQUIPMENT
c.
d.
e.
3.7
Clean, pretreat, prime and paint metal surfaces; except aluminum surfaces need not be painted. Apply coatings to clean dry surfaces. Clean the surfaces to remove dust, dirt, rust, oil and grease by wire brushing and solvent degreasing prior to application of paint, except clean to bare metal on metal surfaces subject to temperatures in excess of 120 degrees F. Where more than one coat of paint is specified, apply the second coat after the preceding coat is thoroughly dry. Lightly sand damaged painting and retouch before applying the succeeding coat. Provide aluminum or light gray finish coat. a. Temperatures less than 120 degrees F: Immediately after cleaning, apply one coat of pretreatment primer applied to a minimum dry film thickness of 0.3 mil, one coat of primer applied to a minimum dry film thickness of one mil; and two coats of enamel applied to a minimum dry film thickness of one mil per coat to metal surfaces subject to temperatures less than 120 degrees F. Temperatures between 120 and 400 degrees F: Apply two coats of 400 degrees F heat-resisting enamel applied to a total minimum thickness of two mils to metal surfaces subject to temperatures between 120 and 400 degrees F. Temperatures greater than 400 degrees F: SECTION 23 00 00 Apply two coats of 315
b.
c.
Page 50
123044
degrees C 600 degrees F heat-resisting paint applied to a total minimum dry film thickness of two mils to metal surfaces subject to temperatures greater than 400 degrees F. 3.8 IDENTIFICATION SYSTEMS
Provide identification tags made of brass, engraved laminated plastic, or engraved anodized aluminum, indicating service and item number on all valves and dampers. Provide tags that are 1-3/8 inch minimum diameter with stamped or engraved markings. Make indentations black for reading clarity. Attach tags to valves with No. 12 AWG 0.0808-inch diameter corrosion-resistant steel wire, copper wire, chrome-plated beaded chain or plastic straps designed for that purpose. 3.9 DUCTWORK LEAK TESTS
The requirements for ductwork leak tests are specified in Section 23 05 93 TESTING, ADJUSTING AND BALANCING FOR HVAC. 3.10 DAMPER ACCEPTANCE TEST
Submit the proposed schedule, at least 2 weeks prior to the start of test. Operate all fire dampers and smoke dampers under normal operating conditions, prior to the occupancy of a building to determine that they function properly. Test each fire damper equipped with fusible link by having the fusible link cut in place. Test dynamic fire dampers with the air handling and distribution system running. Reset all fire dampers with the fusible links replaced after acceptance testing. To ensure optimum operation and performance, install the damper so it is square and free from racking. 3.11 TESTING, ADJUSTING, AND BALANCING
The requirements for testing, adjusting, and balancing are specified in Section 23 05 93 TESTING, ADJUSTING AND BALANCING FOR HVAC. Begin testing, adjusting, and balancing only when the air supply and distribution, including controls, has been completed, with the exception of performance tests. 3.12 PERFORMANCE TESTS
After testing, adjusting, and balancing is complete as specified, test each system as a whole to see that all items perform as integral parts of the system and temperatures and conditions are evenly controlled throughout the building. Record the testing during the applicable season. Make corrections and adjustments as necessary to produce the conditions indicated or specified. Conduct capacity tests and general operating tests by an experienced engineer. Provide tests that cover a period of not less than [_____]2 days for each system and demonstrate that the entire system is functioning according to the specifications. Make coincidental chart recordings at points indicated on the drawings for the duration of the time period and record the temperature at space thermostats or space sensors, the humidity at space humidistats or space sensors and the ambient temperature and humidity in a shaded and weather protected area. Submit test reports for the [ductwork leak test, and] performance tests in booklet form, upon completion of testing. Document phases of tests performed including initial test summary, repairs/adjustments made, and final test results in the reports. SECTION 23 00 00 Page 51
123044
3.13
CLEANING AND ADJUSTING
Provide a temporary bypass for water coils to prevent flushing water from passing through coils. Inside of fan powered variable volume boxes and all other similar air moving equipment,[room fan-coil units][coil-induction units,] [air terminal units,] [unit ventilators,] thoroughly clean ducts, plenums, and casing of debris and blow free of small particles of rubbish and dust and then vacuum clean before installing outlet faces. Wipe equipment clean, with no traces of oil, dust, dirt, or paint spots. Provide temporary filters prior to startup of all fans that are operated during construction, and install new filters after all construction dirt has been removed from the building, and the ducts, plenums, casings, and other items specified have been vacuum cleaned. Maintain system in this clean condition until final acceptance. Properly lubricate bearings with oil or grease as recommended by the manufacturer. Tighten belts to proper tension. Adjust control valves and other miscellaneous equipment requiring adjustment to setting indicated or directed. Adjust fans to the speed indicated by the manufacturer to meet specified conditions. Maintain all equipment installed under the contract until close out documentation is received, the project is completed and the building has been documented as beneficially occupied. 3.14 3.14.1 OPERATION AND MAINTENANCE Operation and Maintenance Manuals
Submit [six] [_____] manuals at least 2 weeks prior to field training. Submit data complying with the requirements specified in Section 01 78 2 4.05 203 FACILITY OPERATION AND MAINTENANCE DATASUPPORT INFORMATION. Submit Data Package 3 for the items/units listed under SD-10 Operation and Maintenance Data 3.14.2 Operation And Maintenance Training
Conduct a training course for the members of the operating staff as designated by the Contracting Officer. Make the training period consist of a total of [_____]8 hours of normal working time and start it after all work specified herein is functionally completed and the Performance Tests have been approved. Conduct field instruction that covers all of the items contained in the Operation and Maintenance Manuals as well as demonstrations of routine maintenance operations. Submit the proposed On-site Training schedule concurrently with the Operation and Maintenance Manuals and at least 14 days prior to conducting the training course. -- End of Section --
SECTION 23 00 00
Page 52
123044
SECTION 23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS 08/10 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. ASTM INTERNATIONAL (ASTM) ASTM B 117 (2009) Standing Practice for Operating Salt Spray (Fog) Apparatus
1.2
RELATED REQUIREMENTS
This section applies to all sections of Divisions: 21, FIRE SUPPRESSION; 22, PLUMBING; and 23, HEATING, VENTILATING, AND AIR CONDITIONING of this project specification, unless specified otherwise in the individual section. 1.3 1.3.1 QUALITY ASSURANCE Material and Equipment Qualifications
Provide materials and equipment that are standard products of manufacturers regularly engaged in the manufacture of such products, which are of a similar material, design and workmanship. Standard products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2-year use shall include applications of equipment and materials under similar circumstances and of similar size. The product shall have been for sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2 year period. 1.3.2 Alternative Qualifications
Products having less than a two-year field service record will be acceptable if a certified record of satisfactory field operation for not less than 6000 hours, exclusive of the manufacturer's factory or laboratory tests, can be shown. 1.3.3 Service Support
The equipment items shall be supported by service organizations. Submit a certified list of qualified permanent service organizations for support of the equipment which includes their addresses and qualifications. These service organizations shall be reasonably convenient to the equipment installation and able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract. 1.3.4 Manufacturer's Nameplate
Each item of equipment shall have a nameplate bearing the manufacturer's name, address, model number, and serial number securely affixed in a conspicuous place; the nameplate of the distributing agent will not be SECTION 23 03 00.00 20 Page 1
123044
acceptable. 1.3.5 Modification of References
In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word, "shall" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction", or words of similar meaning, to mean the Contracting Officer. 1.3.5.1 Definitions
For the International Code Council (ICC) Codes referenced in the contract documents, advisory provisions shall be considered mandatory, the word "should" shall be interpreted as "shall." Reference to the "code official" shall be interpreted to mean the "Contracting Officer." For Navy owned property, references to the "owner" shall be interpreted to mean the "Contracting Officer." For leased facilities, references to the "owner" shall be interpreted to mean the "lessor." References to the "permit holder" shall be interpreted to mean the "Contractor." 1.3.5.2 Administrative Interpretations
For ICC Codes referenced in the contract documents, the provisions of Chapter 1, "Administrator," do not apply. These administrative requirements are covered by the applicable Federal Acquisition Regulations (FAR) included in this contract and by the authority granted to the Officer in Charge of Construction to administer the construction of this project. References in the ICC Codes to sections of Chapter 1, shall be applied appropriately by the Contracting Officer as authorized by his administrative cognizance and the FAR.
1.4
DELIVERY, STORAGE, AND HANDLING
Handle, store, and protect equipment and materials to prevent damage before and during installation in accordance with the manufacturer's recommendations, and as approved by the Contracting Officer. Replace damaged or defective items. [1.5 ELECTRICAL REQUIREMENTS
Furnish motors, controllers, disconnects and contactors with their respective pieces of equipment. Motors, controllers, disconnects and contactors shall conform to and have electrical connections provided under Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Furnish internal wiring for components of packaged equipment as an integral part of the equipment. Extended voltage range motors will not be permitted. Controllers and contactors shall have a maximum of 120 volt control circuits, and shall have auxiliary contacts for use with the controls furnished. When motors and equipment furnished are larger than sizes indicated, the cost of additional electrical service and related work shall be included under the section that specified that motor or equipment. Power wiring and conduit for field installed equipment shall be provided under and conform to the requirements of Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. ] [1.7 ELECTRICAL INSTALLATION REQUIREMENTS
Electrical installations shall conform to IEEE C2, NFPA 70, and SECTION 23 03 00.00 20 Page 2
123044
requirements specified herein. 1.7.1 New Work
Provide electrical components of mechanical equipment, such as motors, motor starters [(except starters/controllers which are indicated as part of a motor control center)], control or push-button stations, float or pressure switches, solenoid valves, integral disconnects, and other devices functioning to control mechanical equipment, as well as control wiring and conduit for circuits rated 100 volts or less, to conform with the requirements of the section covering the mechanical equipment. Extended voltage range motors shall not be permitted. The interconnecting power wiring and conduit, control wiring rated 120 volts (nominal) and conduit, [the motor control equipment forming a part of motor control centers,] and the electrical power circuits shall be provided under Division 26, except internal wiring for components of package equipment shall be provided as an integral part of the equipment. When motors and equipment furnished are larger than sizes indicated, provide any required changes to the electrical service as may be necessary and related work as a part of the work for the section specifying that motor or equipment. 1.7.2 Modifications to Existing Systems
Where existing mechanical systems and motor-operated equipment require modifications, provide electrical components under Division 26. 1.7.3 1.7.3.1 High Efficiency Motors High Efficiency Single-Phase Motors
Unless otherwise specified, single-phase fractional-horsepower alternating-current motors shall be high efficiency types corresponding to the applications listed in NEMA MG 11. 1.7.3.2 High Efficiency Polyphase Motors
Unless otherwise specified, polyphase motors shall be selected based on high efficiency characteristics relative to the applications as listed in NEMA MG 10. Additionally, polyphase squirrel-cage medium induction motors with continuous ratings shall meet or exceed energy efficient ratings in accordance with Table 12-6C of NEMA MG 1. 1.7.4 Three-Phase Motor Protection
Provide controllers for motors rated one 1 horsepower and larger with electronic phase-voltage monitors designed to protect motors from phase-loss, undervoltage, and overvoltage. Provide protection for motors from immediate restart by a time adjustable restart relay. ]1.6 INSTRUCTION TO GOVERNMENT PERSONNEL
When specified in other sections, furnish the services of competent instructors to give full instruction to the designated Government personnel in the adjustment, operation, and maintenance, including pertinent safety requirements, of the specified equipment or system. Instructors shall be thoroughly familiar with all parts of the installation and shall be trained in operating theory as well as practical operation and maintenance work. Instruction shall be given during the first regular work week after the SECTION 23 03 00.00 20 Page 3
123044
equipment or system has been accepted and turned over to the Government for regular operation. The number of man-days (8 hours per day) of instruction furnished shall be as specified in the individual section. When more than 4 man-days of instruction are specified, use approximately half of the time for classroom instruction. Use other time for instruction with the equipment or system. When significant changes or modifications in the equipment or system are made under the terms of the contract, provide additional instruction to acquaint the operating personnel with the changes or modifications. 1.7 ACCESSIBILITY
Install all work so that parts requiring periodic inspection, operation, maintenance, and repair are readily accessible. Install concealed valves, expansion joints, controls, dampers, and equipment requiring access, in locations freely accessible through access doors. PART 2 PRODUCTS
Not Used PART 3 3.1 EXECUTION PAINTING OF NEW EQUIPMENT
New equipment painting shall be factory applied or shop applied, and shall be as specified herein, and provided under each individual section. 3.1.1 Factory Painting Systems
Manufacturer's standard factory painting systems may be provided subject to certification that the factory painting system applied will withstand 125 hours in a salt-spray fog test, except that equipment located outdoors shall withstand 500 hours in a salt-spray fog test. Salt-spray fog test shall be in accordance with ASTM B 117, and for that test the acceptance criteria shall be as follows: immediately after completion of the test, the paint shall show no signs of blistering, wrinkling, or cracking, and no loss of adhesion; and the specimen shall show no signs of rust creepage beyond 0.125 inch on either side of the scratch mark. The film thickness of the factory painting system applied on the equipment shall not be less than the film thickness used on the test specimen. If manufacturer's standard factory painting system is being proposed for use on surfaces subject to temperatures above 120 degrees F, the factory painting system shall be designed for the temperature service. 3.1.2 Shop Painting Systems for Metal Surfaces
Clean, pretreat, prime and paint metal surfaces; except aluminum surfaces need not be painted. Apply coatings to clean dry surfaces. Clean the surfaces to remove dust, dirt, rust, oil and grease by wire brushing and solvent degreasing prior to application of paint, except metal surfaces subject to temperatures in excess of 120 degrees F shall be cleaned to bare metal. Where more than one coat of paint is specified, apply the second coat after the preceding coat is thoroughly dry. Lightly sand damaged painting and retouch before applying the succeeding coat. Color of finish coat shall be SECTION 23 03 00.00 20 Page 4
123044
aluminum or light gray. a. Temperatures Less Than 120 Degrees F: Immediately after cleaning, the metal surfaces subject to temperatures less than 120 degrees F shall receive one coat of pretreatment primer applied to a minimum dry film thickness of 0.3 mil, one coat of primer applied to a minimum dry film thickness of 1 mil; and two coats of enamel applied to a minimum dry film thickness of 1 mil per coat. Temperatures Between 120 and 400 Degrees F: Metal surfaces subject to temperatures between 120 and 400 degrees F shall receive two coats of 400 degrees F heat-resisting enamel applied to a total minimum thickness of 2 mils. Temperatures Greater Than 400 Degrees F: Metal surfaces subject to temperatures greater than 400 degrees F shall receive two coats of 600 degrees F heat-resisting paint applied to a total minimum dry film thickness of 2 mils. -- End of Section --
b.
c.
SECTION 23 03 00.00 20
Page 5
123044
SECTION 23 05 48.00 40 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT 02/11 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. ACOUSTICAL SOCIETY OF AMERICA (ASA) ASA S2.71 (1983; R 2006) Guide to the Evaluation of Human Exposure to Vibration in Buildings
AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE) ASHRAE HVAC APP IP HDBK (2007; Errata 2010) HVAC Applications Handbook, I-P Edition
NATIONAL ENVIRONMENTAL BALANCING BUREAU (NEBB) NEBB PROCEDURAL STANDARDS (2005) Procedural Standards for TAB (Testing, Adjusting and Balancing) Environmental Systems
1.2
GENERAL REQUIREMENTS
Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS applies to work specified in this section to the extent applicable. Section 23 05 1564 26 COMMON PIPING FOR HVACCHILLED AND CONDENSER HEAT RECLAIM WATER PIPING SYSTEMS applies to work specified in this section to the extent applicable. All vibration-control apparatus must be the product of a single manufacturing source, where possible. Human exposure levels should be considered using ASA S2.71 and NEBB PROCEDURAL STANDARDS. Scheduled isolation mounting is in inches and is a minimum static deflection. Spans referred to in Part 2, "Vibration-Isolation Systems Application," must mean longest bay dimension. Determine exact mounting sizes and number of isolators by the isolator manufacturer based on equipment that will be installed. Check equipment revolutions per minute (rpm) and spring deflections to verify that resonance cannot occur. Five [_____] working days prior to commencement of installation, submit installation drawings for vibration isolator systems including equipment and performance requirements.
SECTION 23 05 48.00 40
Page 1
123044
Indicate within outline drawings for vibration isolator systems, overall physical features, dimensions, ratings, service requirements, and weights of equipment. Within ten [_____] working days of Contract Award, submit equipment and performance data for vibration isolator systems including equipment base design; inertia-block mass relative to support equipment weight; spring loads and free, operating, and solid heights of spring; spring diameters; nonmetallic isolator loading and deflection; disturbing frequency; natural frequency of mounts; deflection of working member; and anticipated amount of physical movement at the reference points. Ensure data includes the following: a. b. c. d. e. 1.3 Mountings Bases Isolators Floor-Mounted Piping Vertical Piping SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are [for Contractor Quality Control approval.][for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] Submit the following in accordance with Section 01 33 00.0 50 2006 CONSTRUCTION SUBMITTAL PROCEDURES: SD-02 Shop Drawings Installation Drawings Outline Drawings SD-03 Product Data Equipment and Performance Data Isolators SD-06 Test Reports Type of Isolator Type of Base Allowable Deflection Measured Deflection
SECTION 23 05 48.00 40
Page 2
123044
PART 2 2.1
PRODUCTS TYPE OF VIBRATION-ISOLATION PROVISIONS
Design for vibration isolation using NEBB PROCEDURAL STANDARDS or ASHRAE HVAC APP IP HDBK, Chapter 37,[NEBB PROCEDURAL STANDARDS] [ ASHRAE HVAC APP IP HDBK, Chapter 37,] as applicable to the following sections. Submit test reports for testing vibration isolation for each type of isolator and each type of base, and meet referenced standards contained within this section. Include in test reports allowable deflection and measured deflection also meeting referenced standards within this section. 2.1.1 Materials
Rubber must be natural rubber. Elastomer must be chloroprene. Shore A durometer measurement of both materials and range between 40 and 60. Inorganic materials such as precompressed, high-density, fibrous glass encased in a resilient moisture-impervious membrane may be used in lieu of specified natural rubber and elastomers. Where this substitution is made, ensure specified deflections are modified by the manufacturing source to accommodate physical characteristics of inorganic materials and to provide equal or better vibration isolation. Ensure weather-exposed metal vibration-isolator parts are corrosion protected. Chloroprene coat springs. 2.1.2 Mountings
Provide the following mountings as required for each application: [ Type A: Composite pad, with 0.25-inch thick elastomer top and bottom layers, molded to contain a pattern with nonslip characteristics in all horizontal directions. Elastomer loading must not exceed 40 pounds per square inch (psi). Minimum overall thickness must be 1 inch. Maximum deflections up to 0.25-inch are allowed. Type B: Double [rubber-in-shear] [elastomer-in-shear] with molded-in steel reinforcement in top and bottom. Maximum deflections up to 0.50 inch are allowed. Type C: Free-standing laterally stable open-spring type for deflections over 0.50 inch, with built-in bearing and leveling provisions, 0.25-inch thick Type A base elastomer pads, and accessories. Outside diameter of each spring must be equal to or greater than 0.9 times the operating height of the spring under rated load. Type D: Partially housed type, containing one or more vertically restrained springs with at least 0.50 inch clearance maintained around springs, with adjustable limit stops, 0.25-inch thick Type A base elastomer pads, and accessories. Type E: Pendulum-suspension configuration with free-standing stable spring with resilient horizontal and vertical restraints to allow maximum movements of 0.25 inch in each direction, 0.25-inch thick Type A base elastomer pads. SECTION 23 05 48.00 40 Page 3
][
][
][
][
123044
][
Type F: Combination [spring and rubber-in-shear] [elastomer-in-shear] steel framed for hanger-rod mounting. Minimum total static deflection must be 1 inch. Type G: Air spring with body constructed of reinforced elastomer specifically suitable for application environment. Select air spring to provide a natural frequency equal to 5 inches of deflection of conventional specified steel springs. Provide facilities for dead-level adjustment and height-control of supported equipment. Bases
] [
]2.1.3
Provide the following bases as required for each application: [ Type U: Unit isolators without rails, structural-steel bases, or inertia blocks. Type R: Rails, [connected] [disconnected] mill-rolled structural steel, of sufficient dimension to preclude deflection at midpoint of unsupported span in excess of 1/1,440th of the span between isolators, power transmission, component misalignment, and any overhung weight. Where Type R bases are specified and the equipment proposed requires additional base support, use a Type S base. Type S: Structural-steel bases common to a supported assembly, made from welded-joint mill-rolled structural steel with closed-perimeter configuration, isolators attached to outrigger supports. Height of steel members must be sufficient to provide stiffness required to maintain equipment manufacturer's recommended alignment and duty efficiency of power-transmission components. Height of steel member must not result in member deflection at midpoint of unsupported span of more than 1/1,440th of the span between isolators. Minimum height must be 5 inches. Type CIB: Concrete inertia blocks must be common to the entire assembly, and have welded-joint construction, mill-rolled structural-steel perimeters, welded-in No. 4 reinforcing bars 8 inches on center each way near the bottom of the block, outrigger-isolator mounting provisions, anchor bolts, and be filled with 3,000 psi cured-strength concrete. Configuration of inertia bases must be rectangular to accommodate equipment supported. Minimum thickness of inertia base, in addition to providing suitable mass, must be sufficient to provide stiffness to maintain equipment manufacturer's recommended alignment and duty efficiency of power-transmission components. Minimum thickness must be sufficient to result in base deflection at midpoint of unsupported span of not more than 1/1,440th of the span between isolators. Minimum thickness, the preceding requirements not withstanding, must be 8 percent of the longest base dimension. Pumps with flexible couplings must not have inertia bases less than 8 inches thick. Minimum mass of concrete inertia block must be equal in weight to supported SECTION 23 05 48.00 40 Page 4
][
][
123044
equipment. 2.2 VIBRATION-ISOLATION SYSTEMS APPLICATION
Vibration isolation design per NEBB PROCEDURAL STANDARDS or ASHRAE HVAC APP IP HDBK, Chapter 37, and ASA S2.40[NEBB PROCEDURAL STANDARDS ][ ASHRAE HVAC APP IP HDBK, Chapter 37,] [ASA S2.40]. 2.2.1 Centrifugal Water Chiller Package Locations ON GRADE BASEMENT 20-FOOT TYPE BELOW-GRADE FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* Hermetic Open Type A-U-0.25 B-U-0.38 B-U-0.50 D-U-1.0 ON GRADE 30-FOOT FLOOR-SPAN PROVISIONS* D-S-1.75 D-CIB-1.75 ON GRADE 40-FOOT FLOOR-SPAN PROVISIONS* D-S-2.5 D-CIB-2.5
*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.2.2 Reciprocating Water Chiller Package Locations ON GRADE BASEMENT 20-FOOT TYPE BELOW-GRADE FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* 500 to 750 rpm 750 rpm and over ON GRADE 30-FOOT FLOOR-SPAN PROVISIONS* ON GRADE 40-FOOT FLOOR-SPAN PROVISIONS*
D-U-1.0
D-U-1.5
D-S-2.5
D-CIB-2.75
D-U-1.0
D-U-1.0
D-R-2.0
D-CIB-2.5
*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.2.3 Absorption Water Chiller Package Locations ON GRADE BASEMENT 20-FOOT TYPE BELOW-GRADE FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* Standard A-U-0.25 D-U-1.0 ON GRADE 30-FOOT FLOOR-SPAN PROVISIONS* D-U-1.5 ON GRADE 40-FOOT FLOOR-SPAN PROVISIONS* D-U-2.75
*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.2.4 Reciprocating Compressor/Condenser Locations ON GRADE BASEMENT 20-FOOT TYPE BELOW-GRADE FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* 500 to 750 rpm 750 to and over ON GRADE 30-FOOT FLOOR-SPAN PROVISIONS* ON GRADE 40-FOOT FLOOR-SPAN PROVISIONS*
D-U-1.0
D-U-1.5
D-U-2.5
D-CIB-2.75
D-U-1.0
D-U-1.0
D-U-2.0 Page 5
D-CIB-2.5
SECTION 23 05 48.00 40
123044
ON GRADE BASEMENT 20-FOOT TYPE BELOW-GRADE FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS*
ON GRADE 30-FOOT FLOOR-SPAN PROVISIONS*
ON GRADE 40-FOOT FLOOR-SPAN PROVISIONS*
*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.2.5 Reciprocating Refrigeration Compressor Locations ON GRADE BASEMENT 20-FOOT TYPE BELOW-GRADE FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* 500 to 750 rpm 750 rpm and over ON GRADE 30-FOOT FLOOR-SPAN PROVISIONS* ON GRADE 40-FOOT FLOOR-SPAN PROVISIONS*
C-U-1.0
C-U-1.5
C-U-2.5
C-CIB-2.75
C-U-1.0
C-U-1.0
C-U-2.0
C-CIB-2.5
*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.2.1 Centrifugal Pump Locations ON GRADE ON GRADE ON GRADE BASEMENT 20-FOOT 30-FOOT 40-FOOT TYPE BELOW-GRADE FLOOR-SPAN FLOOR-SPAN FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* PROVISIONS* Closecouple through 5 hp Bedplatemounted through 5 hp 7-1/210 hp
None-R-0.35
C-S-1.0
C-S-1.0
NoneC-CIB-1.0
C-CIB-1.5
C-CIB-1.75 C-CIB-2.5
NoneC -CIB -1.0
C-CIB-1.75
*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.2.7 Air-Cooled Condensing Unit Locations 20-FOOT ROOF-SPAN PROVISIONS* 30-FOOT ROOF-SPAN PROVISIONS* 40-FOOT ROOF-SPAN PROVISIONS*
TYPE EQUIPMENT
Through 5 hp over 900 rpm Over 5 hp to 500 rpm 500 rpm and over
B-U-0.5
D-U-1.0
D-U-1.75
B-U-0.5 B-U-0.5
D-U-1.75 D-U-1.0
D-U-2.5 D-U-1.75
SECTION 23 05 48.00 40
Page 6
123044
20-FOOT 30-FOOT 40-FOOT ROOF-SPAN ROOF-SPAN ROOF-SPAN TYPE EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* *TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.2.2 Low-Pressure Suspended Air-Handling Unit (AHU)Fan Powered VAV Locations Vibration-isolation provisions apply to ceiling-suspended Air Moving and Conditioning Association Class A packaged central-station units. 20-FOOT ROOF-SPAN PROVISIONS* F-U-1.0 30-FOOT ROOF-SPAN PROVISIONS* F-U-1.0 40-FOOT ROOF-SPAN PROVISIONS* F-U-1.0
TYPE EQUIPMENT Through 5 hp
7-1/2 hp and over 250 to 500 rpm 500 rpm and over
F-U-1.75 F-U-1.0
F-U-1.75 F-U-1.25
F-U-1.75 F-U-1.55
*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.2.9 Low-Pressure AHU Locations
Vibration-isolation provisions apply to floor-mounted Air Moving and Conditioning Association Class A packaged central-station units. ON GRADE ON GRADE ON GRADE BASEMENT 20-FOOT 30-FOOT 40-FOOT TYPE BELOW-GRADE FLOOR-SPAN FLOOR-SPAN FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* PROVISIONS* Through 5 hp 7-1/2 hp and over 250 to 500 rpm 500 rpm
B-U-0.35 C-U-1.0
C-U-1.0
C-U-1.0
B-U-0.35 C-U-1.75 B-U-0.35 C-U-1.0
C-U-1.75 C-U-1.5
C-U-1.75
*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.2.10 Medium- And High-Pressure AHU Locations
Vibration-isolation provisions apply to floor-mounted Air Moving and Conditioning Association Classes B and C packaged central-station units. ON GRADE ON GRADE ON GRADE BASEMENT 20-FOOT 30-FOOT 40-FOOT TYPE BELOW-GRADE FLOOR-SPAN FLOOR-SPAN FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* PROVISIONS* Through 20 hp SECTION 23 05 48.00 40 Page 7
123044
ON GRADE ON GRADE ON GRADE BASEMENT 20-FOOT 30-FOOT 40-FOOT TYPE BELOW-GRADE FLOOR-SPAN FLOOR-SPAN FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* PROVISIONS* 250 to 300 rpm B-U-0.35 C-U-2.5 C-U-2.5 C-U-3.5 300 to 500 rpm 500 rpm and over Over 20 hp 250 to 300 rpm 300 to 500 rpm 500 rpm and over
B-U-0.35 C-U-1.75
C-U-1.75
C-U-2.5
B-U-0.35 C-U-1.0
C-U-1.0
C-U-1.75
B-U-0.35 C-U-2.5
C-CIB-3.5
C-CIB-3.5
B-U-0.35 C-U-2.5
C-CIB-2.5
C-CIB-3.5
B-U-0.35 C-U-1.0
C-CIB-1.75
C-CIB-2.5
*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.2.3 Air-Moving Device Locations
Vibration-isolation provisions apply to [housed or] [unhoused] free-standing fans of any pressure rating, located in [field-erected [field-] [factory-] fabricated central-station units] [unhoused [return-air] [supply-air] service]. ON GRADE ON GRADE ON GRADE BASEMENT 20-FOOT 30-FOOT 40-FOOT TYPE BELOW-GRADE FLOOR-SPAN FLOOR-SPAN FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* PROVISIONS* Through 20 hp 200 to 300 rpm 300 to 500 rpm 500 rpm and over Over 20 hp 250 to 300 rpm 300 to 500 rpm 500 rpm and over
B-U-0.35 C-S-2.5
C-S-2.5
C-S-3.5
B-U-0.35 C-S-1.75
C-S-1.75
C-S-2.5
B-U-0.35 C-S-1.0
C-S-1.5
C-S-1.75
B-U-0.35 C-S-2.75
C-CIB-3.5
C-CIB-5.0
B-U-0.35 C-S-1.75
C-CIB-2.5
C-CIB-3.5
B-U-0.35 C-S-1.0
C-CIB-1.75
C-CIB-2.5
SECTION 23 05 48.00 40
Page 8
123044
ON GRADE ON GRADE ON GRADE BASEMENT 20-FOOT 30-FOOT 40-FOOT TYPE BELOW-GRADE FLOOR-SPAN FLOOR-SPAN FLOOR-SPAN EQUIPMENT PROVISIONS* PROVISIONS* PROVISIONS* PROVISIONS* *TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.2.4 Cross-Flow Cooling Tower LocationsOutdoor Air Cooled Chiller
Isolate per chiller manufacture's recommendations.
TYPE EQUIPMENT Package under tower base to 500 rpm 500 rpm and over Field erected under tower base; all rpm Under mechanicalequipment supporting frame to 500 rpm 500 rpm and over
20-FOOT ROOF-SPAN PROVISIONS*
B-U-0.35 B-U-0.35
D-U-2.0 D-U-1.0
D-U-2.5 D-U-1.75
*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.2.13 Blow-Through Cooling Tower Locations 20-FOOT ROOF-SPAN PROVISIONS* 30-FOOT ROOF-SPAN PROVISIONS* 40-FOOT ROOF-SPAN PROVISIONS*
TYPE EQUIPMENT Under tower base to 500 rpm 500 rpm and over
B-U-0.35 B-U-0.35
C-S-2.5 C-S-1.0
C-S-3.5 C-S-1.75
*TYPE OF MOUNTING, BASE, AND MINIMUM DEFLECTION IN INCHES 2.3 [ PIPE AND DUCT VIBRATION ISOLATION (as shown or called for on drawings) Type G: Provide isolators with in-series contained steel springs and preformed fibrous-glass or chloroprene-elastomer elements for connecting to building-structure attachments. Load devices by supported system during operating conditions to produce a minimum spring and elastomer static deflection of 1 inch and 3/8 inch, respectively. Type H: Provide isolators with contained chloroprene-elastomer elements for connecting to building-structure attachments. Load SECTION 23 05 48.00 40 Page 9
] [
123044
devices by supported system during operating conditions to produce a minimum elastomer static deflection of 3/8 inch. ][ Type J: Provide isolators with elastomers mounted on floor-supported columns or directly on the floor. Load devices by supported system during operating conditions to produce a minimum elastomer static deflection of 3/8 inch. Floor-Mounted Piping
][2.3.1
Type K: Provide isolators with springs mounted on floor-supported columns or directly on the floor. Load devices by supported system during operating conditions to produce a minimum spring static deflection of 1 inch. ]2.3.2 [ Vertical Piping Type L: Provide isolators which are pipe base-support devices with one or more contained steel springs. Load devices by supported system during operating conditions to produce a minimum static deflection of 1 inch. Equip devices with precompression and vertical-limit features, as well as a minimum 1/4-inch thick elastomer sound pad and isolation washers, for mounting to floor. Type M: Isolators must be elastomer mounted baseplate and riser pipe-guide devices. Elastomer elements must be contained double acting, and elastomers under rated load must have a minimum static deflection of 3/8 inch. Size isolator to accommodate thermal insulation within the stationary guide ring. EXECUTION INSTALLATION
][
] PART 3 3.1
Install equipment in accordance with manufacturer's recommendations. [ Rails, structural steel bases, and concrete inertia blocks must be raised not less than 1 inch above the floor and be level when equipment supported is under operating load. ][Ensure vibration-isolation installation and deflection testing after equipment start-up is directed by a competent representative of the manufacturer. ]3.2 TESTS AND REPORTS
[ Ensure vibration-isolation devices are deflection tested. Submit test reports in accordance with paragraph entitled, "Submittal Procedures," substantiating that all equipment has been isolated as specified and that minimum specified deflections have been met. Make all measurements in the presence of the Contracting Officer. ] -- End of Section --
SECTION 23 05 48.00 40
Page 10
123044
SECTION 23 05 93 TESTING, ADJUSTING, AND BALANCING FOR HVAC 08/09 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. ACOUSTICAL SOCIETY OF AMERICA (ASA) ASA S1.11 (2004; Errata 2005; R 2009) Specification for Octave- Band and Fractional-Octave-Band Analog and Digital Filters (ASA 65) (1983; Amendment 1985; R 2006) Specification for Sound Level Meters (ASA 47) AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA) AMCA 203 (1990) Field Performance Measurements of Fan Systems AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE) ASHRAE HVAC APP IP HDBK (2007; Errata 2010) HVAC Applications Handbook, I-P Edition
ASA S1.4
ASSOCIATED AIR BALANCE COUNCIL (AABC) AABC MN-1 (2002; 6th ed) National Standards for Total System Balance (1996) Test and Balance Procedures
AABC MN-4
NATIONAL ENVIRONMENTAL BALANCING BUREAU (NEBB) NEBB MASV (2006) Procedural Standards for Measurements and Assessment of Sound and Vibration (2005) Procedural Standards for TAB (Testing, Adjusting and Balancing) Environmental Systems
NEBB PROCEDURAL STANDARDS
SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA) SMACNA 1143 (1985) HVAC Air Duct Leakage Test Manual, 1st Edition
SECTION 23 05 93
Page 1
123044
SMACNA 1780
(2002) HVAC Systems - Testing, Adjusting and Balancing, 3rd Edition (2004) HVAC Sound And Vibration Manual First Edition
SMACNA 1858
1.2 a. b. c. d. e.
DEFINITIONS AABC: COTR: DALT: DALT'd: Associated Air Balance Council. Contracting Officer's Technical Representative. Duct air leakage test Duct air leakage tested
HVAC: Heating, ventilating, and air conditioning; or heating, ventilating, and cooling. NEBB: National Environmental Balancing Bureau
f. g.
Out-of-tolerance data: Pertains only to field acceptance testing of Final DALT or TAB report. When applied to DALT work, this phase means "a leakage rate measured during DALT field acceptance testing which exceeds the leakage rate allowed by Appendix D REQUIREMENTS FOR DUCT AIR LEAK TESTING.SMACNA Standards" When applied to TAB work this phase means "a measurement taken during TAB field acceptance testing which does not fall within the range of plus 5 to minus 5 percent of the original measurement reported on the TAB Report for a specific parameter." Season of maximum heating load: The time of year when the outdoor temperature at the project site remains within plus or minus 30 degrees Fahrenheit of the project site's winter outdoor design temperature, throughout the period of TAB data recording. Season of maximum cooling load: The time of year when the outdoor temperature at the project site remains within plus or minus 5 degrees Fahrenheit of the project site's summer outdoor design temperature, throughout the period of TAB data recording. Season 1, Season 2: Depending upon when the project HVAC is completed and ready for TAB, Season 1 is defined, thereby defining Season 2. Season 1 could be the season of maximum heating load, or the season of maximum cooling load. Sound measurements terminology: SMACNA 1858 (TABB). TAB: TAB'd: Defined in AABC MN-1, NEBB MASV, or
h.
i.
j.
k.
l. m. n. o. p.
Testing, adjusting, and balancing (of HVAC systems). HVAC Testing/Adjusting/Balancing procedures performed. TAB Firm TAB team field leaderTAB team field leader. TAB team engineerTAB team engineer.
TAB Agency:
TAB team field leader: TAB team supervisor:
SECTION 23 05 93
Page 2
123044
q. r. 1.2.1
TAB team technicians: TABB:
TAB team assistantsTAB team assistants.
Testing Adjusting and Balancing Bureau.
Similar Terms
In some instances, terminology differs between the Contract and the TAB Standard primarily because the intent of this Section is to use the industry standards specified, along with additional requirements listed herein to produce optimal results. The following table of similar terms is provided for clarification only. Contract requirements take precedent over the corresponding AABC, NEBB, or TABB requirements where differences exist. SIMILAR TERMS Contract Term AABC Term National Standards for Testing and Balancing Heating, Ventilating, and Air Conditioning Systems NEBB Term Procedural Standards for Testing, Adjusting and Balancing of Environmental Systems TABB Term International Standards for Environmental Systems Balance
TAB Standard
TAB Specialist TAB Engineer Systems Readiness Check Construction Phase Inspection
TAB Supervisor Field Readiness Check & Preliminary Field Procedures.
TAB Supervisor Field Readiness Check & Prelim. Field Procedures
1.3
WORK DESCRIPTION
The work includes duct air leakage testing (DALT) and testing, adjusting, and balancing (TAB) of [new][ and existing] heating, ventilating, and cooling (HVAC) air[ and water] distribution systems including ducts, and piping which are located within, on, under, between, and adjacent to buildings. Perform TAB in accordance with the requirements of the TAB procedural standard recommended by the TAB trade association that approved the TAB Firm's qualifications. Comply with requirements of AABC MN-1, NEBB PROCEDURAL STANDARDS, or SMACNA 1780 (TABB) as supplemented and modified by this specification section. All recommendations and suggested practices contained in the TAB procedural standards are considered mandatory.
Conduct DALT and TAB of the indicated existing systems and equipment and submit the specified DALT and TAB reports for approval. Conduct DALT testing in compliance with the requirements specified in SMACNA 1143, except as supplemented and modified by this section. Conduct DALT and TAB work in accordance with the requirements of this section. SECTION 23 05 93 Page 3
123044
1.3.1
Air Distribution Systems
Test, adjust, and balance system[s] (TAB) in compliance with this section. Obtain Contracting Officer's written approval before applying insulation to exterior of air distribution systems as specified under Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. 1.3.2 Water Distribution Systems
TAB system[s] in compliance with this section. Obtain Contracting Officer's written approval before applying insulation to water distribution systems as specified under Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. At Contractor's option and with Contracting Officer's written approval, the piping systems may be insulated before systems are TAB'd. Terminate piping insulation immediately adjacent to each flow control valve, automatic control valve, or device. Seal the ends of pipe insulation and the space between ends of pipe insulation and piping, with waterproof vapor barrier coating. After completion of work under this section, insulate the flow control valves and devices as specified under Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. 1.3.3 Related Requirements
Requirements for price breakdown of HVAC TAB work are specified in Section 01 20 00.005 20 PRICE AND PAYMENT PROCEDURES FOR DESIGN BUILD. Requirements for construction scheduling related to HVAC TAB work are specified in Section 01 32 17.005 20 NETWORK ANALYSIS SCHEDULES (NAS)FOR DESIGN BUILD. 1.4 SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are [for Contractor Quality Control approval.][for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] Submit the following in accordance with Section 01 33 00.05 20 CONSTRUCTION SUBMITTAL PROCEDURES:
SD-06 Test Reports DALT and TAB Work Execution Schedule; G DALT and TAB Procedures Summary; G Design review report; G Pre-Final DALT report; G Final DALT report; G
SECTION 23 05 93
Page 4
123044
TAB report for Season 1; G TAB report for Season 2; G SD-07 Certificates Independent TAB agency and personnel qualifications; G Advance notice of Pre-Final DALT field work; G Completed Pre-Final DALT Work Checklist; G Advance Notice of [Season 1 ]TAB Field Work; G Completed [Season 1 ]Pre-TAB Work Checklist DALT and TAB Submittal and Work Schedule; G Design Review Report; G
[Advance Notice of Season 2 TAB Field Work; G] [Completed Season 2 Pre-TAB Work Checklist]
1.5 1.5.1
QUALITY ASSURANCE Independent TAB Agency and Personnel Qualifications
To secure approval for the proposed agency, submit information certifying that the TAB agency is a first tier subcontractor who is not affiliated with any other company participating in work on this contract, including design, furnishing equipment, or construction. Further, submit the following, for the agency, to Contracting Officer for approval: a. Independent AABC or NEBB or TABB TAB agency: TAB agency: AABC registration number and expiration date of current certification; or NEBB certification number and expiration date of current certification; or TABB certification number and expiration date of current certification. TAB team supervisor: Name and copy of AABC or NEBB or TABB TAB supervisor certificate and expiration date of current certification. TAB team field leader: Name and documented evidence that the team field leader has satisfactorily performed full-time supervision of TAB work in the field for not less than 3 years immediately preceding this contract's bid opening date. TAB team field technicians: Names and documented evidence that each field technician has satisfactorily assisted a TAB team field leader in performance of TAB work in the field for not less than one year immediately preceding this contract's bid opening date. Current certificates: Registrations and certifications are current, and valid for the duration of this contract. Renew Certifications SECTION 23 05 93 Page 5
123044
which expire prior to completion of the TAB work, in a timely manner so that there is no lapse in registration or certification. TAB agency or TAB team personnel without a current registration or current certification are not to perform TAB work on this contract. b. TAB Team Members: TAB team approved to accomplish work on this contract are full-time employees of the TAB agency. No other personnel is allowed to do TAB work on this contract. Replacement of TAB team members: Replacement of members may occur if each new member complies with the applicable personnel qualifications and each is approved by the Contracting Officer. PROJECT/SITE CONDITIONS
c.
[1.6
1.6.1
DALT and TAB Services to Obtain Existing Conditions
Conduct DALT and TAB of the indicated existing systems and equipment and submit the specified DALT and TAB reports for approval. Conduct this DALT and TAB work in accordance with the requirements of this section. ]1.7 1.7.1 SEQUENCING AND SCHEDULING DALT and TAB Submittal and Work Schedule
Comply with additional requirements specified in Appendix C: DALT AND TAB SUBMITTAL AND WORK SCHEDULE included at the end of this section [1.7.2 Projects with Phased Construction
This specification section is structured as though the HVAC construction, and thereby the TAB work, will be completed in a single phase. When the construction is completed in phases, the DALT work and TAB work must be planned, completed, and accepted for each construction phase. 1.7.2.1 Phasing of Work
This specification section is structured as though the HVAC construction, and thereby the TAB work, is going to be completed in a single phase[ in spite of the fact that there will be two seasons]. All elements of the TAB work are addressed on this premise. When a contract is to be completed in construction phases, including the TAB work, and the DALT work, the TAB work and DALT work must be planned for, completed and approved by the Contracting Officer with each phase. An example of this case would be one contract that requires the rehabilitation of the HVAC in each of several separated buildings. At the completion of the final phase, compile all approved reports and submit as one document. ]1.7.3 DALT and TAB Submittal and Work Schedule
Submit this schedule,and TAB Schematic Drawings, adapted for this particular contract, to the Contracting Officer (CO) for review and approval. Include with the submittal the planned calendar dates for each submittal or work item. Resubmit an updated version for CO approval every 90 calendar days days. Compliance with the following schedule is the Contractor's responsibility. SECTION 23 05 93 Page 6
123044
Qualify TAB Personnel: Within [45] [_____] calendar days after date of contract award, submit TAB agency and personnel qualifications. Pre-DALT/TAB Meeting: Within [30] [_____] calendar days after the date of approval of the TAB agency and personnel, meet with the COTR. Design Review Report: Within [60] [_____] calendar days after the date of the TAB agency personnel qualifications approval, submit design review report. Pre-Field DALT Preliminary Notification: On completion of the duct installation for each system, notify the Contracting Officer in writing within 5 days after completion. Ductwork Selected for DALT: Within 7 calendar days of Pre-Field DALT Preliminary Notification, the COTR will select which of the project ductwork must be DALT'd. DALT Field Work: Within 48 hours of COTR's selection, complete DALT field work on selected. Submit Pre-final DALT Report: Within one working day after completion of DALT field work, submit Pre-final DALT Report. Separate Pre-final DALT reports may be submitted to allow phased testing from system to system. DALT Work Field Check: Upon approval of the Pre-final DALT Report, schedule the COTR's DALT field check work with the Contracting Officer. Submit Final DALT Report: Within [15] [_____] calendar days after completion of successful DALT Work Field Check, submit [Season 1 ] TAB report. Pre-Field TAB Engineering Report: Within [_____] calendar days after approval of the TAB agency Personnel Qualifications, submit the Pre-Field TAB Engineering Report. Prerequisite HVAC Work Check Out List [For Season 1] and Advanced Notice For [Season 1 ] TAB Field Work: At a minimum of [115] [_____] calendar days prior to CCD, submit [Season 1 ] prerequisite HVAC work check out list certified as complete, and submit advance notice of commencement of [Season 1 ] TAB field work. [[Season 1 ] TAB Field Work: At a minimum of [90] [_____] calendar days prior to CCD, [and when the ambient temperature is within Season 1 limits,] accomplish [Season 1 ] TAB field work. Submit [Season 1 ] TAB Report: Within [15] [_____] calendar days after completion of [Season 1 ] TAB field work, submit [Season 1 ] TAB report. [Season 1 ] TAB Field Check: [30] [_____] calendar days after Season 1 TAB report is approved by the Contracting Officer, conduct [Season 1 ] field check. Complete [Season 1 ] TAB Work: Season 2 TAB work].] Prior to CCD, complete all TAB work [except
[[Season 1 ] TAB Field Work: At a minimum of [90] [_____] calendar days prior to CCD, [and when the ambient temperature is within Season 1 SECTION 23 05 93 Page 7
123044
limits,] accomplish [Season 1 ] TAB field work; submit [Season 1 ] TAB report; and conduct [Season 1 ] field check. Complete [Season 1 ] TAB Work: Season 2 TAB work].] Prior to CCD, complete all TAB work [except
[Prerequisite HVAC Work Check Out List For Season 2 and Advanced Notice For Season 2 TAB Field Work: Within [150] [_____] calendar days after date of the commencement of the Season 1 TAB field work, submit the Season 2 prerequisite HVAC work check out list certified as complete and submit advance notice of commencement of Season 2 TAB field work.] [Season 2 TAB Field Work: Within [180] [_____] calendar days after date of commencement of the Season 1 TAB field work and when the ambient temperature is within Season 2 limits, accomplish Season 2 TAB field work. Submit Season 2 TAB Report: Within [15] [_____] calendar days after completion of Season 2 TAB field work, submit Season 2 TAB report. Season 2 TAB Field Check: [30] [_____] calendar days after the Season 2 TAB report is approved by the Contracting Officer, conduct Season 2 field check. Complete Season 2 TAB Work: Within [15] [_____] calendar days after the completion of Season 2 TAB field data check, complete all TAB work.] [Season 2 TAB Field Work: Within [180] [_____] calendar days after date of commencement of the Season 1 TAB field work and when the ambient temperature is within Season 2 limits, accomplish [Season 2 ] TAB field work; submit [Season 2 ] TAB report; and conduct Season 2 field check. Complete Season 2 TAB Work: Within [15] [_____] calendar days after the completion of Season 2 field data check, complete TAB work.] 1.7.3.1 Design Review Report
Submit typed report describing omissions and deficiencies in the HVAC system's design that would preclude the TAB team from accomplishing the duct leakage testing work and the TAB work requirements of this section. Provide a complete explanation including supporting documentation detailing the design deficiency. State that no deficiencies are evident if that is the case. 1.7.3.2 Pre-Field DALT Preliminary Notification
Notification: On completion of the installation of each duct system indicated to be DALT'd, notify the Contracting Officer in writing within 7 calendar days after completion. 1.7.3.3 Pre-Field TAB Engineering Report
Submit report containing the following information: a. Step-by-step TAB procedure: (1) Strategy: Describe the method of approach to the TAB field work from start to finish. Include in this description a complete methodology for accomplishing each seasonal TAB field work session. SECTION 23 05 93 Page 8
123044
(2) Air System Diagrams: Use the contract drawings and duct fabrication drawings if available to provide air system diagrams in the report showing the location of all terminal outlet supply, return, exhaust and transfer registers, grilles and diffusers. Use a key numbering system on the diagrams which identifies each outlet contained in the outlet airflow report sheets. Show intended locations of all traverses and static pressure readings. (3) Procedural steps: Delineate fully the intended procedural steps to be taken by the TAB field team to accomplish the required TAB work of each air distribution system and each water distribution system. Include intended procedural steps for TAB work for subsystems and system components. b. Pre-field data: Submit AABC or NEBB or SMACNA 1780 data report forms with the following pre-field information filled in: (1) Design data obtained from system drawings, specifications, and approved submittals. Notations detailing additional data to be obtained from the contract site by the TAB field team. Designate the actual data to be measured in the TAB field work. Provide a list of the types of instruments, and the measuring range of each, which are anticipated to be used for measuring in the TAB field work. By means of a keying scheme, specify on each TAB data report form submitted, which instruments will be used for measuring each item of TAB data. If the selection of which instrument to use, is to be made in the field, specify from which instruments the choice will be made. Place the instrument key number in the blank space where the measured data would be entered.
(2)
(3) (4)
c.
Prerequisite HVAC work checkout list: Provide a list of inspections and work items which are to be completed by the Contractor. This list must be acted upon and completed by the Contractor and then submitted and approved by the Contracting Officer prior to the TAB team coming to the contract site. At a minimum, a list of the applicable inspections and work items listed in the NEBB PROCEDURAL STANDARDS, Section III, "Preliminary TAB Procedures" under paragraphs titled, "Air Distribution System Inspection" and "Hydronic Distribution System Inspection" must be provided for each separate system to be TAB'd.
1.6
SUBCONTRACTOR SPECIAL REQUIREMENTS
[Perform all work in this section in accordance with the paragraph entitled "Subcontractor Special Requirements" in Section 01 30 00.05 20 ADMINISTRATIVE REQUIREMENTS FOR DESIGN BUILD, stating that all contract requirements of this section must be accomplished directly by a first tier subcontractor. No work may be performed by a second tier subcontractor.] PART 2 PRODUCTS
Not Used
SECTION 23 05 93
Page 9
123044
PART 3 3.1
EXECUTION WORK DESCRIPTIONS OF PARTICIPANTS
Comply with requirements of this section as specified in Appendix A WORK DESCRIPTIONS OF PARTICIPANTS. 3.2 PRE-DALT/TAB MEETING
Meet with the Contracting Officer's technical representative (COTR)[and the designing engineer of the HVAC systems] to develop a mutual understanding relative to the details of the DALT work and TAB work requirements. Ensure that the TAB supervisor is present at this meeting. Requirements to be discussed include required submittals, work schedule, and field quality control. 3.3 3.3.1 DALT PROCEDURES Instruments, Consumables and Personnel
Provide instruments, consumables and personnel required to accomplish the DALT field work. Follow the same basic procedure specified below for TAB Field Work, including maintenance and calibration of instruments, accuracy of measurements, preliminary procedures, field work, workmanship and treatment of deficiencies. Calibrate and maintain instruments in accordance with manufacturer's written procedures. 3.3.2 Advance Notice of Pre-Final DALT Field Work
On completion of the installation of each duct system indicated to be DALT'd, notify the Contracting Officer in writing prior to the COTR's duct selection field visit. 3.3.3 Ductwork To Be DALT'd
From each duct system indicated as subject to DALT, the COTR will randomly select sections of each completed duct system for testing by the Contractor's TAB Firm. The sections selected will not exceed 20 percent of the total measured linear footage of duct systems indicated as subject to DALT. Sections of duct systems subject to DALT will include 20 percent of main ducts, branch main ducts, branch ducts and plenums for supply, return, exhaust, and plenum ductwork. [ It is acceptable for an entire duct system to be DALT'd instead of disassembling that system in order to DALT only the 20 percent portion specified above.] 3.3.4 DALT Testing
Perform DALT on the HVAC duct sections of each system as selected by the COTR. Use the duct class, seal class, leakage class and the leak test pressure data indicated on the drawings, to comply with the procedures specified in SMACNA 1143. In spite of specifications of SMACNA 1143 to the contrary, DALT ductwork of construction class of 31-inch water gauge static pressure and below if indicated to be DALT'dgreater. Complete DALT work on the COTR selected ductwork within 48 hours after the particular ductwork was selected for DALT. Separately conduct DALT work for large duct systems to enable the SECTION 23 05 93 Page 10
123044
DALT work to be completed in 48 hours. 3.3.5 Pre-final DALT Report
After completion of the DALT work, prepare a Pre-final DALT Report meeting the additional requirements specified in Appendix B REPORTS - DALT and TAB. Data required by those data report forms shall be furnished by the TAB team. Prepare the report neatly and legibly; the Pre-final DALT report shall provide the basis for the Final DALT Report. TAB supervisor shall review, approve and sign the Pre-Final DALT Report and submit this report within one day of completion of DALT field work. Verbally notify the COTR that the field check of the Pre-Final DALT Report data can commence.
3.3.6
Quality Assurance - COTR DALT Field Acceptance Testing
In the presence of the COTR and TAB team field leader, verify for accuracy Pre-final DALT Report data selected by the COTR. For each duct system, this acceptance testing shall be conducted on a maximum of 50 percent of the duct sections DALT'd. Further, if any data on the Pre-final DALT report form for a given duct section is out-of-tolerance, then field acceptance testing shall be conducted on data for one additional duct section, preferably in the same duct system, in the presence of the COTR. 3.3.7 Additional COTR Field Acceptance Testing
If any of the duct sections checked for a given system are determined to have a leakage rate measured that exceeds the leakage rate allowed by SMACNA Leak Test Manual for an indicated duct construction class and sealant class, terminate data checking for that section. The associated Pre-final DALT Report data for the given duct system will be disapproved. Make the necessary corrections and prepare a revised Pre-final DALT Report. Reschedule a field check of the revised report data with the COTR. 3.3.8 Certified Final DALT Report
On successful completion of all field checks of the Pre-Final DALT Report data for all systems, the TAB Supervisor shall assemble, review, approve, sign and submit the Final DALT Report in compliance with Appendix B REPORTS - DALT and TAB to the Contracting Officer for approval. 3.3.9 Prerequisite for TAB Field Work
Do not commence TAB field work prior to the completion and approval, for all systems, of the Final DALT Report. 3.4 3.4.1 TAB PROCEDURES TAB Field Work
Test, adjust, and balance the HVAC systems until measured flow rates (air and water flow) are within plus or minus 5 percent of the design flow rates as specified or indicated on the contract documents.
SECTION 23 05 93
Page 11
123044
That is, comply with the the requirements of AABC MN-1 , or SMACNA 1780 (TABB) and SMACNA 1858 (TABB),except as supplemented and modified by this section. [ Provide instruments and consumables required to accomplish the TAB work. Calibrate and maintain instruments in accordance with manufacturer's written procedures.] Test, adjust, and balance the HVAC systems until measured flow rates (air and water flow) are within plus or minus 5 percent of the design flow rates as specified or indicated on the contract documents. Conduct TAB work, including measurement accuracy, and sound measurement work in conformance with the AABC MN-1 and AABC MN-4, or NEBB TABES and NEBB MASV, or SMACNA 1780 (used by TABB) and SMACNA 1858 sound measurement procedures, except as supplemented and modified by this section.[ The only water flow and air flow reporting which can be deferred until the Season 2 is that data which would be affected in terms of accuracy due to outside ambient conditions.] 3.4.2 Preliminary Procedures
Use the approved pre-field engineering report as instructions and procedures for accomplishing TAB field work. TAB engineer is to locate, in the field, test ports required for testing. It is the responsibility of the sheet metal contractor to provide and install test ports as required by the TAB engineer. 3.4.3 3.4.3.1 TAB Air Distribution Systems Units With Coils
Report heating and cooling performance capacity tests for hot water, chilled water, DX and steam coils for the purpose of verifying that the coils meet the indicated design capacity. Submit the following data and calculations with the coil test reports: a. For air handlers with capacities greater than 7.5 tons (90,000 Btu) cooling, such as factory manufactured units, central built-up units and rooftop units, conduct capacity tests in accordance with AABC MN-4, procedure 3.5, "Coil Capacity Testing." Do not determine entering single point measurement, compliance with paragraph AABC MN-4, Procedure 3.5, and leaving wet and dry bulb temperatures by but by the average of multiple readings in 3.5-5, "Procedures", (in subparagraph d.) of "Coil Capacity Testing."
Submit part-load coil performance data from the coil manufacturer converting test conditions to design conditions; use the data for the purpose of verifying that the coils meet the indicated design capacity in compliance with AABC MN-4, Procedure 3.5, "Coil Capacity Testing," paragraph 3.5.7, "Actual Capacity Vs. Design Capacity" (in subparagraph c.). b. For units with capacities of 7.5 tons (90,000 Btu) or less, such as fan coil units, duct mounted reheat coils associated with VAV terminal units, and unitary units, such as through-the-wall heat pumps: Determine the apparent coil capacity by calculations using single point measurement of entering and leaving wet and dry bulb temperatures; submit the calculations with the coil reports. SECTION 23 05 93 Page 12
123044
3.4.3.2
Air Handling Units
Air handling unit systems including fans (air handling unit fans, exhaust fans and winter ventilation fans), coils, ducts, plenums, mixing boxes, terminal units, variable air volume boxes, and air distribution devices for supply air, return air, outside air, mixed air relief air, and makeup air. [3.4.3.3 Rooftop Air Conditioning
Rooftop air conditioning systems including fans, coils, ducts, plenums, and air distribution devices for supply air, return air, and outside air. For refrigeration compressors/condensers/condensing units/evaporators, report data as required by NEBB, AABC, and TABB standard procedures, including refrigeration operational data. ][3.4.3.4 Heating and Ventilating Units
Heating and ventilating unit systems including fans, coils, ducts, plenums, roof vents, registers, diffusers, grilles, and louvers for supply air, return air, outside air, and mixed air. ][3.4.3.3 Makeup Air Units
Makeup air unit systems including fans, coils, ducts, plenums, registers, diffusers, grilles, and louvers for supply air, return air, outside air, and mixed air. ][3.4.3.4 Return Air Fans
Return air fan system including fan ducts, plenums, registers, diffusers, grilles, and louvers for supply air, return air, outside air, and mixed air. ][3.4.3.7 Fan Coils
Fan coil unit systems including fans, coils, ducts, plenums, and air distribution devices for supply air, return air, and outside air. ][3.4.3.5 Exhaust Fans
Exhaust fan systems including fans, ducts, plenums, grilles, and hoods for exhaust air. ][3.4.4 3.4.4.1 TAB Water Distribution Systems Chilled Water
Chilled water systems including chillers, condensers, cooling towers, pumps, coils, system balance valves and flow measuring devices. For water chillers, report data as required by AABC, NEBB and TABB standard procedures, including refrigeration operational data. 3.4.4.2 Heating Hot Water
Heating hot water systems including boilers, hot water converters (e.g., heat exchangers), pumps, coils, system balancing valves and flow measuring devices. SECTION 23 05 93 Page 13
123044
3.4.4.3
Dual Temperature Water
Dual temperature water systems including boilers, converters, chillers, condensers, cooling towers, pumps, coils, and system balancing valves, and flow measuring devices. ][3.4.5 3.4.5.1 Sound Measurement Work Areas To Be Sound Measured
In the following spaces, measure and record the sound power level for each octave band listed in ASHRAE HVAC APP IP HDBK Noise Criteria: a. All HVAC mechanical rooms, including machinery spaces and other spaces containing HVAC power drivers and power driven equipment. All spaces sharing a common barrier with each mechanical room, including rooms overhead, rooms on the other side of side walls, and rooms beneath the mechanical room floor. AHU No. 1 System: [_____] System: [_____] System: Procedure Rooms: [_____]] Rooms: [_____]] Rooms: [_____]]
b.
[c. [d. [e. 3.4.5.2
Measure sound levels in each room, when unoccupied except for the TAB team, with all HVAC systems that would cause sound readings in the room operating in their noisiest mode. Record the sound level in each octave band. Attempt to mitigate the sound level and bring the level to within the specified ASHRAE HVAC APP IP HDBK noise criteria goals, if such mitigation is within the TAB team's control. State in the report the ASHRAE HVAC APP IP HDBK noise criteria goals. If sound level cannot be brought into compliance, provide written notice of the deficiency to the Contractor for resolution or correction. 3.4.5.3 Timing
Measure sound levels at times prescribed by AABC or NEBB or TABB. 3.4.5.4 Meters
Measure sound levels with a sound meter complying with ASA S1.4, Type 1 or 2, and an octave band filter set complying with ASA S1.11. Use measurement methods for overall sound levels and for octave band sound levels as prescribed by NEBB. 3.4.5.5 Calibration
Calibrate sound levels as prescribed by AABC or NEBB or TABB, except that calibrators emitting a sound pressure level tone of 94 dB at 1000 hertz (Hz) are also acceptable. 3.4.5.6 Background Noise Correction
Determine background noise component of room sound (noise) levels for each SECTION 23 05 93 Page 14
123044
(of eight) octave bands as prescribed by AABC or NEBB or TABB. ][3.4.6 3.4.6.1 TAB Work on Performance Tests Without Seasonal Limitations Performance Tests
In addition to the TAB proportionate balancing work on the air distribution systems and the water distribution systems, accomplish TAB work on the HVAC systems which directly transfer thermal energy. TAB the operational performance of the [heating systems] [and] [cooling systems]. 3.4.6.2 Ambient Temperatures
On each tab report form used for recording data, record the outdoor and indoor ambient dry bulb temperature range and the outdoor and indoor ambient wet bulb temperature range within which the report form's data was recorded. Record these temperatures at beginning and at the end of data taking. [3.4.6.3 Sound Measurements
Comply with paragraph entitled "Sound Measurement Work," specifically, the requirement that a room must be operating in its noisiest mode at the time of sound measurements in the room. The maximum noise level measurements could depend on seasonally related heat or cooling transfer equipment. ][3.4.6 3.4.6.1 TAB Work on Performance Tests With Seasonal Limitations Performance Tests
Accomplish proportionate balancing TAB work on the air distribution systems and water distribution systems, in other words, accomplish adjusting and balancing of the air flows and water flows, any time during the duration of this contract, subject to the limitations specified elsewhere in this section. However, accomplish, within the following seasonal limitations, TAB work on HVAC systems which directly transfer thermal energy. 3.4.6.2 Season Of Maximum Load
Visit the contract site for at least two TAB work sessions for TAB field measurements. [Visit the contract site during the season of maximum heating load] [and] [visit the contract site during the season of maximum cooling load], the goal being to TAB the operational performance of the [ heating systems] [and] [cooling systems] under their respective maximum outdoor environment-caused loading. During the seasonal limitations, TAB the operational performance of the [heating systems] [and] [cooling systems]. 3.4.6.3 Ambient Temperatures
On each tab report form used for recording data, record the outdoor and indoor ambient dry bulb temperature range and the outdoor and indoor ambient wet bulb temperature range within which the report form's data was recorded. Record these temperatures at beginning and at the end of data taking. 3.4.6.4 Sound Measurements
Comply with paragraph entitled "Sound Measurement Work," specifically, the requirement that a room must be operating in its noisiest mode at the time SECTION 23 05 93 Page 15
123044
of sound measurements in the room. The maximum noise level measurements could depend on seasonally related heat or cooling transfer equipment. ][3.4.7 Workmanship
Conduct TAB work on the HVAC systems until measured flow rates are within plus or minus 5 percent of the design flow rates as specified or indicated on the contract documents. This TAB work includes adjustment of balancing valves, balancing dampers, and sheaves. Further, this TAB work includes changing out fan sheaves and pump impellers if required to obtain air and water flow rates specified or indicated. If, with these adjustments and equipment changes, the specified or indicated design flow rates cannot be attained, contact the Contracting Officer for direction. ]3.4.8 Deficiencies
Strive to meet the intent of this section to maximize the performance of the equipment as designed and installed. However, if deficiencies in equipment design or installation prevent TAB work from being accomplished within the range of design values specified in the paragraph entitled "Workmanship," provide written notice as soon as possible to the Contractor and the Contracting Officer describing the deficiency and recommended correction. Responsibility for correction of installation deficiencies is the Contractor's. If a deficiency is in equipment design, call the TAB team supervisor for technical assistance. Responsibility for reporting design deficiencies to Contractor is the TAB team supervisor's. 3.4.9 TAB Reports Appendix B
Additional requirements for TAB Reports are specified in REPORTS - DALT and TAB 3.4.10 3.4.10.1
Quality Assurance - COTR TAB Field Acceptance Testing TAB Field Acceptance Testing
During the field acceptance testing, verify, in the presence of the COTR, random selections of data (water, air quantities, air motion, [sound level readings]) recorded in the TAB Report. Points and areas for field acceptance testing are to be selected by the COTR. Measurement and test procedures are the same as approved for TAB work for the TAB Report. Field acceptance testing includes verification of TAB Report data recorded for the following equipment groups: Group 1: All chillers, boilers, return fans, computer room units, and air handling units (rooftop and central stations). Group 2: 25 percent of the VAV terminal boxes and associated diffusers and registers. Group 3: 25 percent of the supply diffusers, registers, grilles associated with constant volume air handling units. Group 4: 25 percent of the return grilles, return registers, exhaust grilles and exhaust registers.
SECTION 23 05 93
Page 16
123044
Group 5:
25 percent of the supply fans, exhaust fans, and pumps.
Further, if any data on the TAB Report for Groups 2 through 5 is found not to fall within the range of plus 5 to minus 5 percent of the TAB Report data, additional group data verification is required in the presence of the COTR. Verify TAB Report data for one additional piece of equipment in that group. Continue this additional group data verification until out-of-tolerance data ceases to be found. 3.4.10.2 Additional COTR TAB Field Acceptance Testing
If any of the acceptance testing measurements for a given equipment group is found not to fall within the range of plus 5 to minus 5 percent of the TAB Report data, terminate data verification for all affected data for that group. The affected data for the given group will be disapproved. Make the necessary corrections and prepare a revised TAB Report. Reschedule acceptance testing of the revised report data with the COTR.
3.4.10.3
Prerequisite for Approval
Compliance with the field acceptance testing requirements of this section is a prerequisite for the final Contracting Officer approval of the TAB Report submitted. 3.5 MARKING OF SETTINGS
Upon the final TAB work approval, permanently mark the settings of HVAC adjustment devices including valves, gauges, splitters, and dampers so that adjustment can be restored if disturbed at any time. Provide permanent markings clearly indicating the settings on the adjustment devices which result in the data reported on the submitted TAB report. 3.6 MARKING OF TEST PORTS
The TAB team is to permanently and legibly mark and identify the location points of the duct test ports. If the ducts have exterior insulation, make these markings on the exterior side of the duct insulation. Show the location of test ports on the as-built mechanical drawings with dimensions given where the test port is covered by exterior insulation. 3.7 APPENDICES A B C D WORK DESCRIPTIONS OF PARTICIPANTS REPORTS - DALT and TAB DALT AND TAB SUBMITTAL AND WORK SCHEDULE REQUIREMENTS FOR DUCT AIR LEAK TESTING
Appendix Appendix Appendix Appendix
SECTION 23 05 93
Page 17
123044
Appendix A WORK DESCRIPTIONS OF PARTICIPANTS The Contractor is responsible for ensuring compliance with all requirements of this specification section. However, the following delineation of specific work items is provided to facilitate and co-ordinate execution of the various work efforts by personnel from separate organizations. 1. a. Contractor HVAC documentation: Provide pertinent contract documentation to the TAB Firm, to include the following: the contract drawings and specifications; copies of the approved submittal data for all HVAC equipment, air distribution devices, and air/water measuring/balancing devices; the construction work schedule; and other applicable documents requested by the TAB Firm. Provide the TAB Firm copies of contract revisions and modifications as they occur. Schedules: Ensure the requirements specified under the paragraph "DALT and TAB Schedule" are met. Pre-DALT and TAB meeting: Arrange and conduct the Pre-DALT and TAB meeting. Ensure that a representative is present for the sheet metal contractor, the mechanical contractor, the electrical contractor, and the automatic temperature controls contractor. Coordinate Support: Provide and coordinate support personnel required by the TAB Firm in order to accomplish the DALT and TAB field work. Support personnel may include factory representatives, HVAC controls installers, HVAC equipment mechanics, sheet metal workers, pipe fitters, and insulators. Ensure support personnel are present at the work site at the times required. Correct Deficiencies: Ensure the notifications of Construction Deficiencies are provided as specified herein. Refer to the paragraph entitled "Construction Deficiencies." Correct each deficiency as soon as practical with the Contracting Officer, and submit revised schedules and other required documentation. Pre-TAB Work Checklists: Complete check out and debugging of HVAC equipment, ducts, and controls prior to the TAB engineer arriving at the project site to begin the TAB work. Debugging includes searching for and eliminating malfunctioning elements in the HVAC system installations, and verifying all adjustable devices are functioning as designed. Include as pre-TAB work checklist items, the deficiencies pointed out by the TAB team supervisor in the design review report.
b.
c.
d.
e.
f.
Prior to the TAB field team's arrival, ensure completion of the applicable inspections and work items listed in the TAB team supervisor's DALT and TAB Work Procedures Summary. Do not allow the TAB team to commence TAB field work until all of the following are completed. g. Give Notice of Testing: Submit advance notice of TAB field work accompanied by completed prerequisite HVAC Work List Insulation work: Ensure that no insulation is shall not be installed on ducts to be DALT'd until DALT work on the subject ducts is complete. SECTION 23 05 93 Page 18
h.
123044
Ensure the duct and piping systems are properly insulated and vapor sealed upon the successful completion and acceptance of the DALT and TAB work. 2. a. TAB Team Supervisor Overall management: Supervise and manage the overall TAB team work effort, including preliminary and technical DALT and TAB procedures and TAB team field work. Schedule: Ensure the requirements specified under the paragraph "DALT and TAB Schedule" are met. Submittals: Provide the submittals specified herein.
b.
c. d.
Pre-DALT/TAB meeting: Attend meeting with Contractor. Ensure TAB personnel that will be involved in the TAB work under this contract attend the meeting. Design Review Report: Submit typed report describing omissions and deficiencies in the HVAC system's design that would preclude the TAB team from accomplishing the duct leakage testing work and the TAB work requirements of this section. Provide a complete explanation including supporting documentation detailing the design deficiency. State that no deficiencies are evident if that is the case. Support required: Specify the technical support personnel required from the Contractor other than the TAB agency; such as factory representatives for temperature controls or for complex equipment. Inform the Contractor in writing of the support personnel needed and when they are needed. Furnish the notice as soon as the need is anticipated, either with the design review report, or the DALT and TAB Procedures Summary, the during the DALT or TAB field work. Ensure the Contractor is properly notified and aware of all support personnel needed to perform the TAB work. Maintain communication with the Contractor regarding support personnel throughout the duration of the TAB field work, including the TAB field acceptance testing checking. Ensure all inspections and verifications for the Pre-Final DALT and Pre-TAB Checklists are completely and successfully conducted before DALT and TAB field work is performed.
e.
f.
g.
Advance Notice: Monitor the completion of the duct system installations and provide the Advance Notice for Pre-Final DALT field work as specified herein. Technical Assistance: field work. Provide technical assistance to the DALT and TAB
h.
i.
Deficiencies Notification: Ensure the notifications of Construction Deficiencies are provided as specified herein. Comply with requirements of the paragraph entitled "Construction Deficiencies." Resolve each deficiency as soon as practical and submit revised schedules and other required documentation.
j. Procedures: Develop the required TAB procedures for systems or system components not covered in the TAB Standard. SECTION 23 05 93 Page 19
123044
3. a.
TAB Team Field Leader Field manager: Manage, in the field, the accomplishment of the work specified in Part 3, "Execution." Full time: Be present at the contract site when DALT field work or TAB field work is being performed by the TAB team; ensure day-to-day TAB team work accomplishments are in compliance with this section. Prerequisite HVAC work: Do not bring the TAB team to the contract site until a copy of the prerequisite HVAC work list, with all work items certified by the Contractor to be working as designed, reaches the office of the TAB Agency.
b.
c.
SECTION 23 05 93
Page 20
123044
Appendix B REPORTS - DALT and TAB
All submitted documentation must be typed, neat, and organized. All reports must have a waterproof front and back cover, a title page, a certification page, sequentially numbered pages throughout, and a table of contents. Tables, lists, and diagrams must be titled. Generate and submit for approval the following documentation: 1. DALT and TAB Work Execution Schedule
Submit a detailed schedule indicating the anticipated calendar date for each submittal and each portion of work required under this section. For each work entry, indicate the support personnel (such as controls provider, HVAC mechanic, etc.) that are needed to accomplish the work. Arrange schedule entries chronologically. 2. DALT and TAB Procedures Summary
Submit a detailed narrative describing all aspects of the DALT and TAB field work to be performed. Clearly distinguish between DALT information and TAB information. Include the following: a. A list of the intended procedural steps for the DALT and TAB field work from start to finish. Indicate how each type of data measurement will be obtained. Include what Contractor support personnel are required for each step, and the tasks they need to perform. A list of the project's submittals that are needed by the TAB Firm in order to meet this Contract's requirements. The schematic drawings to be used in the required reports, which may include building floor plans, mechanical room plans, duct system plans, and equipment elevations. Indicate intended TAB measurement locations, including where test ports need to be provided by the Contractor. The data presentation forms to be used in the report, with the preliminary information and initial design values filled in. A list of DALT and TAB instruments to be used, edited for this project, to include the instrument name and description, manufacturer, model number, scale range, published accuracy, most recent calibration date, and what the instrument will be used for on this project. A thorough checklist of the work items and inspections that need to be accomplished before DALT field work can be performed. The Contractor must complete, submit, and receive approval of the Completed Pre-Final DALT Work Checklist before DALT field work can be accomplished. A thorough checklist of the work items and inspections that need to be accomplished before the [Season 1 ]TAB field work can be performed. The Contractor must complete, submit, and receive approval of the Completed [Season 1 ]Pre-TAB Work Checklist before the [Season 1 ]TAB field work can be accomplished. A thorough checklist of the work items and inspections that need to be SECTION 23 05 93 Page 21
b.
c.
d.
e.
f.
g.
[h.
123044
accomplished before the Season 2 TAB field work can be performed. The Contractor must complete, submit, and receive approval of the Completed Season 2 Pre-TAB Work Checklist before the Season 2 TAB field work can be accomplished.] i. The checklists specified above shall be individually developed and tailored specifically for the work under this contract. Refer to NEBB PROCEDURAL STANDARDS, Section III, "Preliminary TAB Procedures" under the paragraphs titled, "Air Distribution System Inspection" and "Hydronic Distribution System Inspection" for examples of items to include in the checklists. Design Review Report
3.
Submit report containing the following information: a. Review the contract specifications and drawings to verify that the TAB work can be successfully accomplished in compliance with the requirements of this section. Verify the presence and location of permanently installed test ports and other devices needed, including gauge cocks, thermometer wells, flow control devices, circuit setters, balancing valves, and manual volume dampers. Submit a typed report describing omissions and deficiencies in the HVAC system's design that would preclude the TAB team from accomplishing the DALT work and the TAB work requirements of this section. Provide a complete explanation including supporting documentation detailing the design deficiency. If no deficiencies are evident, state so in the report. Pre-Final DALT Report for COTR DALT Field Checks
b.
4.
Report the data for the Pre-Final DALT Report meeting the following requirements: a. Submit a copy of the approved DALT and TAB Procedures Summary: Provide notations describing how actual field procedures differed from the procedures listed. Report format: Submit a comprehensive report for the DALT field work data using data presentation forms equivalent to the "Air Duct Leakage Test Summary Report Forms" located in the SMACNA 1143. In addition, submit in the report, a marked duct shop drawing which identifies each section of duct tested with assigned node numbers for each section. Node numbers shall be included in the completed report forms to identify each duct section. Calculations: Include a copy of all calculations prepared in determining the duct surface area of each duct test section. Include in the DALT reports copy(s) of the calibration curve for each of the DALT test orifices used for testing. Instruments: List the types of instruments actually used to measure the data. Include in the listing each instrument's unique identification number, calibration date, and calibration expiration date. Instruments are to be calibrated within one year of the date of use in the field; instrument calibration is to be traceable to the measuring standards of the National Institute of Standards and Technology. SECTION 23 05 93 Page 22
b.
c.
d.
123044
e.
TAB Supervisor Approval: Include on the submitted report the typed name of the TAB supervisor and the dated signature of the TAB supervisor. Final DALT Report
5.
On successful completion of all COTR field checks of the Pre-final DALT Report data for all systems, the TABS Supervisor shall assemble, review, sign and submit the Final DALT Report to the Contracting Officer for approval. 6. TAB Reports: Submit TAB Report for Season 1 and TAB Report for Season 2 in the following manner: a. Procedure Summary: Submit a copy of the approved DALT and TAB Procedures Summary. When applicable, provide notations describing how actual field procedures differed from the procedures listed. Report format: Submit the completed data forms approved in the pre-field TAB Engineering Report completed by TAB field team, reviewed, approved and signed by the TAB supervisor. Bind the report with a waterproof front and back cover. Include a table of contents identifying by page number the location of each report. Report forms and report data shall be typewritten. Handwritten report forms or report data are not acceptable. Temperatures: On each TAB report form reporting TAB work accomplished on HVAC thermal energy transfer equipment, include the indoor and outdoor dry bulb temperature range and indoor and outdoor wet bulb temperature range within which the TAB data was recorded. Include in the TAB report continuous time versus temperature recording data of wet and dry bulb temperatures for the rooms, or zones, as designated in the following list:
b.
c.
[_____] (1) Data shall be measured and compiled on a continuous basis for the period in which TAB work affecting those rooms is being done. Data shall be measured/recorded only after the HVAC systems installations are complete, the systems fully balanced and the HVAC systems controls operating in fully automatic mode. Provide a detailed explanation wherever a final measurement did not achieve the required value. Data may be compiled using direct digital controls trend logging where available. Otherwise, the Contractor shall temporarily install calibrated time versus temperature/humidity recorders for this purpose. The HVAC systems and controls shall have been fully operational a minimum of 24 hours in advance of commencing data compilation. The specified data shall be included in the [Season I TAB Report] [Season I and Season 2 TAB Report].
(2)
(3)
d. Air System Diagrams: Provided updated diagrams with final installed locations of all terminals and devices, any numbering changes, and actual test locations. e. Air Static Pressure Profiles: Report static pressure profiles for air Page 23
SECTION 23 05 93
123044
duct systems including: [AHU-1, 2, DOAS-1,2.][RTAC-1][MUA-1][_____]. Report static pressure data for all supply, return, relief, exhaust and outside air ducts for the systems listed. The static pressure report data shall include, in addition to AABC or NEBB or TABB required data, the following: (1) Report supply fan, return fan, relief fan, and exhaust fan inlet and discharge static pressures. Report static pressure drop across chilled water coils, DX coils, hot water coils, steam coils, electric resistance heating coils and heat reclaim devices installed in unit cabinetry or the system ductwork. Report static pressure drop across outside air, return air, and supply air automatic control dampers, both proportional and two-position, installed in unit cabinetry. Report static pressure drop across air filters, acoustic silencers, moisture eliminators, air flow straighteners, air flow measuring stations or other pressure drop producing specialty items installed in unit cabinetry, or in the system ductwork. Examples of these specialty items are smoke detectors, white sound generators, RF shielding, wave guides, security bars, blast valves, small pipes passing through ductwork, and duct mounted humidifiers.
(2)
(3)
(4)
Do not report static pressure drop across duct fittings provided for the sole purpose of conveying air, such as elbows, transitions, offsets, plenums, manual dampers, and branch takes-offs. (5) Report static pressure drop across outside air and relief/exhaust air louvers. Report static pressure readings of supply air, return air, exhaust/relief air, and outside air in duct at the point where these ducts connect to each air moving unit.
(6)
[f.
Duct Transverses: Report duct traverses for main [and branch main] supply, return[, exhaust, relief and outside air] ducts. [This shall include all ducts, including those which lack 7 1/2 duct diameters upstream and 2 1/2 duct diameters downstream of straight duct unobstructed by duct fittings/offsets/elbows.] The TAB Agency shall evaluate and report findings on the duct traverses taken. Evaluate the suitability of the duct traverse measurement based on satisfying the qualifications for a pitot traverse plane as defined by AMCA 203, "Field Measurements", Section 8, paragraph 8.3, "Location of Traverse Plane".] Instruments: List the types of instruments actually used to measure the tab data. Include in the listing each instrument's unique identification number, calibration date, and calibration expiration date.
g.
Instrumentation, used for taking wet bulb temperature readings shall provide accuracy of plus or minus 5 percent at the measured face velocities. Submit instrument manufacturer's literature to document instrument accuracy performance is in compliance with that specified.
SECTION 23 05 93
Page 24
123044
h.
Performance Curves: The TAB Supervisor shall include, in the TAB Reports, factory pump curves and fan curves for pumps and fans TAB'd on the job. Calibration Curves: The TAB Supervisor shall include, in the TAB Reports, a factory calibration curve for installed flow control balancing valves, flow venturis and flow orifices TAB'd on the job. Data From TAB Field Work: After completion of the TAB field work, prepare the TAB field data for TAB supervisor's review and approval signature, using the reporting forms approved in the pre-field engineering report. Data required by those approved data report forms shall be furnished by the TAB team. Except as approved otherwise in writing by the Contracting Officer, the TAB work and thereby the TAB report shall be considered incomplete until the TAB work is accomplished to within the accuracy range specified in the paragraph entitled "Workmanship."
i.
j.
SECTION 23 05 93
Page 25
123044
Appendix C DALT AND TAB SUBMITTAL AND WORK SCHEDULE Perform the following items of work in the order listed adhering to the dates schedule specified below. Include the major items listed in this schedule in the project network analysis schedule required by Section 01 32 17.005 20 NETWORK ANALYSIS SCHEDULES (NAS)FOR DESIGN-BUILD. Submit TAB Agency and TAB Personnel Qualifications: calendar days after date of contract award. Within [42] [_____]
Submit the DALT and TAB Work Execution Schedule: within [14] [_____] days after receipt of the TAB agency and TAB personnel qualifications approval. Revise and re-submit this schedule 28 days prior to commencement of DALT work and 28 days prior to the commencement of TAB Season 1 work and TAB Season 2 work. Submit the DALT and TAB Work Procedures Summary: within [14] [_____] after receipt of the initial approved DALT and TAB Work Execution Schedule. days
Meet with the COTR at the Pre-DALT/TAB Meeting: Within [28] [_____] calendar days after receipt of the approved initial DALT/TAB Execution Schedule. Submit Design Review Report: Within [56] [_____] calendar days after the receipt of the approved initial DALT and TAB Work Execution Schedule. [Conduct measurements and submit the Record of Existing Facility Conditions: within [28] [_____] days after receipt of approved DALT and TAB Work Procedures Summary.] Advance Notice of Pre-Final DALT Field Work: After the completed installation of the HVAC duct system to be DALT'd, submit to the Contracting Officer an Advance Notice of Pre-Final DALT Field Work accompanied by the completed Pre-Final DALT Work Checklistchecklist for the subject duct system. Ductwork Selected for DALT: Within 14 calendar days after receiving an acceptable completed Pre-Final DALT Work Checklist, the Contracting Officer's technical representative (COTR) will select the project ductwork sections to be DALT'd. DALT Field Work: Within 48 hours of COTR's selection, complete DALT field work on selected project ductwork. Submit Pre-Final DALT Report: Within two working days after completion of DALT field work, submit Pre-final DALT Report. Separate Pre-final DALT reports may be submitted to allow phased testing from system to system. Quality Assurance - COTR DALT Field Checks: Upon approval of the Pre-final DALT Report, the COTR's DALT field check work shall be scheduled with the Contracting Officer. Submit Final DALT Report: Within [14] [_____] calendar days after completion of successful DALT Work Field Check, submit [Season 1 ]TAB report. SECTION 23 05 93 Page 26
123044
Advance Notice of [Season 1 ]TAB Field Work: At a minimum of [14][_____] calendar days prior to [Season 1 ]TAB Field Work, submit advance notice of TAB field work accompanied by completed [Season 1 ]Pre-TAB Work Checklist. [Season 1 ]TAB Field Work: At a minimum of [84][_____] calendar days prior to CCD, [and when the ambient temperature is within Season 1 limits,] accomplish [Season 1 ]TAB field work. Submit [Season 1 ]TAB Report: Within [14] [_____] calendar days after completion of [Season 1 ]TAB field work, submit initial [Season 1 ]TAB report. [Season 1 ]Quality Assurance - COTR TAB Field Check: [30] [_____] calendar days after initial [Season 1 ]TAB report is approved by the Contracting Officer, conduct [Season 1 ]field check. Complete [Season 1 ]TAB Work: Prior to CCD, complete all TAB work [except Season 2 TAB work] and submit final. Receive the approved TAB report: Within 21 calendar days, receive the report from Contracting Officer approved TAB report. Advance Notice of Season 2 TAB Field Work: At a minimum of [126] [_____] calendar days after CCD, submit advance notice of Season 2 TAB field work accompanied by completed Season 2 Pre-TAB Work Checklist. [Season 2 TAB Field Work: Within [14] [_____] calendar days after date of advance notice of Season 2 TAB field work and when the ambient temperature is within Season 2 limits, accomplish Season 2 TAB field work. Submit Season 2 TAB Report: Within [14] [_____] calendar days after completion of Season 2 TAB field work, submit Season 2 TAB report. Season 2 Quality Assurance - COTR TAB Field Checks: [28] [_____] calendar days after the Season 2 TAB report is approved by the Contracting Officer, conduct Season 2 field check. Complete Season 2 TAB Work: Within [14] [_____] calendar days after the completion of Season 2 TAB field data check, complete all TAB work.] Receive the approved TAB report: Within calendar 21 days, receive the report from Contracting Officer.
SECTION 23 05 93
Page 27
123044
SECTION 23 05 93
Page 28
123044
APPENDIX D REQUIREMENTS FOR DUCT AIR LEAK TESTING
DOAS-1, 2 Exhaust Duct System Duct System Static Pressure in Inches W.C. 2" 1"
Duct Seal Class Round and Rectangular
System SMACNA Leak Class 12
12
Duct Test Pressure in Inches W.C.
Appendix D REQUIREMENTS FOR DUCT AIR LEAK TESTING | SYSTEMS | |===============================================| | [Package | [Package | [Package | [Package | | Rooftop | Rooftop | Rooftop | Rooftop | | w/VAV | w/VAV | w/CV | w/CV | | Unit No. | Unit No. | Unit No. | Unit No. | | [1][__]] | [2][__]] | [1][__]] | [2][__]] | ============================================================================| Duct System Static | | | | | Pressure in inches W.C. | | | | | for Supply | [4][_] | [4][_] | [2][_] | [2][_] | for Return | [2][_] | [2][_] | [1][_] | [1][_] | for Exhaust | [__] | [__] | [__] | [__] | for Outside Air | [2][_] | [2][_] | [1][_] | [1][_] | | | | | | ============================================================================| System Oval/Round Duct | | | | | and Rectangular Duct | | | | | SMACNA Seal Class | | | | | for Supply | A | A | A | A | for Return | A | A | A | A | SECTION 23 05 93 Page 29
123044
| A | A | A | A | | A | A | A | A | | | | | | ============================================================================| System Oval/Round Duct | | | | | SMACNA Leak Class | | | | | for Supply | [3][_] | [3][_] | [6][_] | [6][_] | for Return | [6][_] | [6][_] | [12][__] | [12][__] | for Exhaust | [__] | [__] | [__] | [__] | for Outside Air | [6][_] | [6][_] | [12][__] | [12][__] | | | | | | ============================================================================| System Rectangular Duct | | | | | SMACNA Leak Class | | | | | for Supply | [6][_] | [6][_] | [12][__] | [12][__] | for Return | [12][__] | [12][__] | [24][__] | [24][__] | for Exhaust | [__] | [__] | [__] | [__] | for Outside Air | [12][__] | [12][__] | [24][__] | [24][__] | | | | | | ============================================================================| Duct Test Pressure | | | | | in inches W.C. | | | | | for Supply | [4][_] | [4][_] | [2][_] | [2][_] | for Return | [2][_] | [2][_] | [1][_] | [1][_] | for Exhaust | [__] | [__] | [__] | [__] | for Outside Air | [2][_] | [2][_] | [1][_] | [1][_] | | | | | | ============================================================================|
for Exhaust for Outside Air
SECTION 23 05 93
Page 30
123044
Appendix D REQUIREMENTS FOR DUCT AIR LEAK TESTING | SYSTEMS | |===============================================| | [AHU w/ | [AHU w/ |[Series VAV| [Exhaust | |Economizer |Economizer | Terminal | Systems | | & CV | & CV | Boxes | | | Unit No. | Unit No. | Unit No. | Unit No. | | [1][__]] | [2][__]] | [1][__]] | [1][__]] | ============================================================================| Duct System Static | | | | | Pressure in inches W.C. | | | | | for Supply.......| [2][_] | [2][_] | [0.5][__] | n/a | for Return.......| [1][_] | [1][_] | [0.5][__] | n/a | for Exhaust......| [0.5][__] | [0.5][__] | n/a | [1][_] | for Outside Air..| [1][_] | [1][_] | n/a | n/a | | | | | | ============================================================================| System Oval/Round Duct | | | | | and Rectangular Duct | | | | | SMACNA Seal Class | | | | | for Supply........| A | A | A | A | for Return........| A | A | A | A | for Exhaust.......| A | A | A | A | for Outside Air...| A | A | A | A | | | | | | ============================================================================| System Oval/Round Duct | | | | | SMACNA Leak Class | | | | | for Supply.......| [6][_] | [6][_] | 12 | n/a | for Return.......| [12][__] | [12][__] | 12 | n/a | for Exhaust......| [12][__] | [12][__] | n/a | [12][__] | for Outside Air..| [12][__] | [12][__] | n/a | n/a | | | | | | ============================================================================| System Rectangular Duct | | | | | SMACNA Leak Class | | | | | for Supply.......| [12][__] | [12][__] | 24 | n/a | for Return.......| [24][__] | [24][__] | 24 | n/a | for Exhaust......| [24][__] | [24][__] | n/a | [24][__] | for Outside Air..| [24][__] | [24][__] | n/a | n/a | | | | | | ============================================================================| Duct Test Pressure | | | | | in inches W.C. | | | | | for Supply.......| [2][_] | [2][_] | [0.5][__] | n/a | for Return.......| [1][_] | [1][_] | [0.5][__] | n/a | for Exhaust......| [0.5][__] | [0.5][__] | n/a | [1][_] | for Outside Air..| [1][_] | [1][_] | n/a | n/a | | | | | | ============================================================================|
-- End of Section --
SECTION 23 05 93
Page 31
123044
SECTION 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS 08/10 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. At the discretion of the Government, the manufacturer of any material supplied will be required to furnish test reports pertaining to any of the tests necessary to assure compliance with the standard or standards referenced in this specification. AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE) ASHRAE 90.1 - IP (2010; INT 1 2011; Errata 2011, Errata 2011) Energy Standard for Buildings Except Low-Rise Residential Buildings
ASTM INTERNATIONAL (ASTM) ASTM A580/A580M (2008) Standard Specification for Stainless Steel Wire (2007) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate (2010) Standard Specification for Flexible, Low Permeance Vapor Retarders for Thermal Insulation (2006e1) Standard Specification for Flexible Fibrous Glass Blanket Insulation Used to Externally Insulate HVAC Ducts (2007) Standard Specification for Mineral Fiber Thermal Insulating Cement (2007) Standard Specification for Mineral Fiber Hydraulic-Setting Thermal Insulating and Finishing Cement (2009) Standard Specification for Calcium Silicate Block and Pipe Thermal Insulation (2008) Standard Specification for Preformed Flexible Elastomeric Cellular Thermal Insulation in Sheet and Tubular Form (2007e1) Standard Specification for Mineral Fiber Pipe Insulation
ASTM B 209
ASTM C 1136
ASTM C 1290
ASTM C 195
ASTM C 449
ASTM C 533
ASTM C 534/C 534M
ASTM C 547
SECTION 23 07 00
Page 1
123044
ASTM C 552
(2007) Standard Specification for Cellular Glass Thermal Insulation (2008) Standard Specification for Mineral Fiber Blanket Thermal Insulation for Commercial and Industrial Applications (2009) Standard Specification for Unfaced Preformed Rigid Cellular Polyisocyanurate Thermal Insulation (2010) Mineral Fiber Block and Board Thermal Insulation (2008) Properties and Tests of Mastics and Coating Finishes for Thermal Insulation (2008) Standard Specification for Thermal Insulation for Use in Contact with Austenitic Stainless Steel (1985; R 2007) Standard Specification for Adhesives for Duct Thermal Insulation (2011) Standard Specification for Elastomeric Joint Sealants (2010) Standard Practice for Determining the Properties of Jacketing Materials for Thermal Insulation (2010) Tensile Properties of Thin Plastic Sheeting (2009) Specimen Preparation and Mounting of Pipe and Duct Insulation Materials to Assess Surface Burning Characteristics (2010b1a) Standard Test Method for Surface Burning Characteristics of Building Materials (2010) Standard Test Methods for Water Vapor Transmission of Materials
ASTM C 553
ASTM C 591
ASTM C 612
ASTM C 647
ASTM C 795
ASTM C 916
ASTM C 920
ASTM C 921
ASTM D 882
ASTM E 2231
ASTM E 84
ASTM E 96/E 96M
FM GLOBAL (FM) FM APP GUIDE (updated on-line) Approval Guide http://www.approvalguide.com/
MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS) MSS SP-69 (2003) Pipe Hangers and Supports Selection and Application (ANSI Approved American National Standard)
SECTION 23 07 00
Page 2
123044
MIDWEST INSULATION CONTRACTORS ASSOCIATION (MICA) MICA Insulation Stds (1999) National Commercial & Industrial Insulation Standards
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA 90A (2009; Errata 09-1) Standard for the Installation of Air Conditioning and Ventilating Systems (2009) Standard for the Installation of Warm Air Heating and Air Conditioning Systems TECHNICAL ASSOCIATION OF THE PULP AND PAPER INDUSTRY (TAPPI) TAPPI T403 OM (2010) Bursting Strength of Paper
NFPA 90B
U.S. DEPARTMENT OF DEFENSE (DOD) MIL-A-24179 (1969; Rev A; Am 2 1980; Notice 1 1987) Adhesive, Flexible Unicellular-Plastic Thermal Insulation (1987; Rev C; Am 2 1990) Adhesives, Fire-Resistant, Thermal Insulation
MIL-A-3316
UNDERWRITERS LABORATORIES (UL) UL 723 (2008; Reprint Sep 2010) Test for Surface Burning Characteristics of Building Materials (1996; R 2003; R 2006; R 2009; R 2010; R 2010) Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances
UL 94
1.2 1.2.1
SYSTEM DESCRIPTION General
Provide field-applied insulation and accessories on mechanical systems as specified herein; factory-applied insulation is specified under the piping, duct or equipment to be insulated. Insulation of heat distributionductwork systems and chilled water systems outside of buildings shall be as specified here in in Section 33 61 13 PRE-ENGINEERED UNDERGROUND HEAT DISTRIBUTION SYSTEM, Section 33 61 15 HEAT DISTRIBUTION SYSTEMS IN CONCRETE TRENCHES, Section 33 60 02ABOVEGROUND HEAT DISTRIBUTION SYSTEM, and Section 33 61 00 PREFABRICATED UNDERGROUND HEATING/COOLING DISTRIBUTION SYSTEM. Field applied insulation materials required for use on Government-furnished items as listed in the SPECIAL CONTRACT REQUIREMENTS shall be furnished and installed by the Contractor. 1.2.2 Surface Burning Characteristics
Unless otherwise specified, insulation shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in SECTION 23 07 00 Page 3
123044
accordance with ASTM E 84. Flame spread, and smoke developed indexes, shall be determined by ASTM E 84 or UL 723. Insulation shall be tested in the same density and installed thickness as the material to be used in the actual construction. Test specimens shall be prepared and mounted according to ASTM E 2231. Insulation materials located exterior to the building perimeter are not required to be fire rated. 1.2.3 Recycled Materials
Provide thermal insulation containing recycled materials to the extent practicable, provided that the materials meets all other requirements of this section. The minimum recycled material content of the following insulation are: Rock Wool - 75 percent slag of weight Fiberglass - 20-25 percent glass cullet by weight Rigid Foam - 9 percent recovered material 1.3 SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for [Contractor Quality Control approval.] [information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] Submit the following in accordance with Section 01 33 00.05 20 00 06 CONSTRUCTION SUBMITTAL PROCEDURES: Submit the threetwo SD types, SD-02 Shop Drawings, SD-03 Product Data, and SD-08 Manufacturer's Instructions at the same time for each system. SD-02 Shop Drawings MICA Plates[; G][; G, [_____]] Pipe Insulation Systems and Associated Accessories Duct Insulation Systems and Associated Accessories Equipment Insulation Systems and Associated Accessories A booklet containing completed MICA Insulation Stds plates detailing each insulating system for each pipe, duct, or equipment insulating system, after approval of materials and prior to applying insulation. a. The MICA plates shall detail the materials to be installed and the specific insulation application. Submit all MICA plates required showing the entire insulating system, including plates required to show insulation penetrations, vessel bottom and top heads, legs, and skirt insulation as applicable. The MICA plates shall present all variations of insulation systems including locations, materials, vaporproofing, jackets and insulation accessories. b. If the Contractor elects to submit detailed drawings instead of edited MICA Plates, the detail drawings shall be technically equivalent to the edited MICA Plate submittal. SD-03 Product Data Pipe Insulation Systems[; G][; G, [_____]] Duct Insulation Systems[; G][; G, [_____]] SECTION 23 07 00 Page 4
123044
Equipment Insulation Systems[; G][; G, [_____]] A complete list of materials, including manufacturer's descriptive technical literature, performance data, catalog cuts, and installation instructions. The product number, k-value, thickness and furnished accessories including adhesives, sealants and jackets for each mechanical system requiring insulation shall be included. The product data must be copyrighted, have an identifying or publication number, and shall have been published prior to the issuance date of this solicitation. Materials furnished under this section of the specification shall be submitted together in a booklet. SD-04 Samples Thermal Insulation[; G][; G, [_____]] After approval of materials, actual sections of installed systems, properly insulated in accordance with the specification requirements, shall be displayed. Such actual sections must remain accessible to inspection throughout the job and will be reviewed from time to time for controlling the quality of the work throughout the construction site. Each material used shall be identified, by indicating on an attached sheet the specification requirement for the material and the material by each manufacturer intended to meet the requirement. The Contracting Officer will inspect display sample sections at the jobsite. Approved display sample sections shall remain on display at the jobsite during the construction period. Upon completion of construction, the display sample sections will be closed and sealed. Pipe Insulation Display Sections: Display sample sections shall include as a minimum an elbow or tee, a valve, dielectric waterways and flanges, a hanger with protection shield and insulation insert, or dowel as required, at support point, method of fastening and sealing insulation at longitudinal lap, circumferential lap, butt joints at fittings and on pipe runs, and terminating points for each type of pipe insulation used on the job, and for hot pipelines and cold pipelines, both interior and exterior, even when the same type of insulation is used for these services. Duct Insulation Display Sections: Display sample sections for rigid and flexible duct insulation used on the job. A temporary covering shall be used to enclose and protect display sections for duct insulation exposed to weather. SD-08 Manufacturer's Instructions Pipe Insulation Systems[; G][; G, [_____]] Duct Insulation Systems[; G][; G, [_____]] Equipment Insulation Systems[; G][; G, [_____]] Submit a booklet containing manufacturer's published installation instructions for the insulation systems. The instructions must be copyrighted, have an identifying or publication number, and shall have been published prior to the issuance date of this solicitation.
SECTION 23 07 00
Page 5
123044
1.4 1.4.1
QUALITY ASSURANCE Installer Qualification
Qualified installers shall have successfully completed three or more similar type jobs within the last 5 years. 1.5 DELIVERY, STORAGE, AND HANDLING
Materials shall be delivered in the manufacturer's unopened containers. Materials delivered and placed in storage shall be provided with protection from weather, humidity, dirt, dust and other contaminants. The Contracting Officer may reject insulation material and supplies that become dirty, dusty, wet, or contaminated by some other means. Packages or standard containers of insulation, jacket material, cements, adhesives, and coatings delivered for use, and samples required for approval shall have manufacturer's stamp or label attached giving the name of the manufacturer and brand, and a description of the material. Insulation packages and containers shall be asbestos free. PART 2 2.1 PRODUCTS STANDARD PRODUCTS
Provide materials which are the standard products of manufacturers regularly engaged in the manufacture of such products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Provide insulation systems in accordance with the approved MICA National Insulation Standards plates as supplemented by this specification. Provide field-applied insulation for heating, ventilating, and cooling (HVAC) air distribution systems and piping systems which are located within, on, under, and adjacent to buildings; and for plumbing systems. Insulation shall be CFC and HCFC free. 2.2 MATERIALS
Provide insulation that meets or exceed the requirements of [ ASHRAE 90.1 - IP][ASHRAE 90.2]. Insulation exterior shall be cleanable, grease resistant, non-flaking and non-peeling. Materials shall be compatible and shall not contribute to corrosion, soften, or otherwise attack surfaces to which applied in either wet or dry state. Materials to be used on stainless steel surfaces shall meet ASTM C 795 requirements. Calcium silicate shall not be used on chilled or cold water systems. Materials shall be asbestos free and conform to the following:Flexible Elastomeric: Closed-cell, foam- or expanded-rubber materials containing anti-microbial additive. Comply with ASTM C 534/C 534M, Type I, Grade 1, for tubular materials and Type II, Grade 1, for sheet materials. Provide product recognized under UL 94 and listed in FM APP GUIDE. 2.2.1 2.2.1.1 Adhesives Acoustical Lining Insulation Adhesive
Adhesive shall be a nonflammable, fire-resistant adhesive conforming to ASTM C 916, Type I. 2.2.1.2 Mineral Fiber Insulation Cement
Cement shall be in accordance with ASTM C 195. SECTION 23 07 00 Page 6
123044
2.2.1.3
Lagging Adhesive
Lagging is the material used for thermal insulation, especially around a cylindrical object. This may include the insulation as well as the cloth/material covering the insulation. Lagging adhesives shall be nonflammable and fire-resistant and shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E 84. Adhesive shall be MIL-A-3316, Class 1, pigmented [white] [red] and be suitable for bonding fibrous glass cloth to faced and unfaced fibrous glass insulation board; for bonding cotton brattice cloth to faced and unfaced fibrous glass insulation board; for sealing edges of and bonding glass tape to joints of fibrous glass board; for bonding lagging cloth to thermal insulation; or Class 2 for attaching fibrous glass insulation to metal surfaces. Lagging adhesives shall be applied in strict accordance with the manufacturer's recommendations for pipe and duct insulation. 2.2.2 Contact Adhesive
Adhesives may be any of, but not limited to, the neoprene based, rubber based, or elastomeric type that have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E 84. The adhesive shall not adversely affect, initially or in service, the insulation to which it is applied, nor shall it cause any corrosive effect on metal to which it is applied. Any solvent dispersing medium or volatile component of the adhesive shall have no objectionable odor and shall not contain any benzene or carbon tetrachloride. The dried adhesive shall not emit nauseous, irritating, or toxic volatile matters or aerosols when the adhesive is heated to any temperature up to 212 degrees F. The dried adhesive shall be nonflammable and fire resistant. Natural cross-ventilation, local (mechanical) pickup, and/or general area (mechanical) ventilation shall be used to prevent an accumulation of solvent vapors, keeping in mind the ventilation pattern must remove any heavier-than-air solvent vapors from lower levels of the workspaces. Gloves and spectacle-type safety glasses are recommended in accordance with safe installation practices. Flexible Elastomeric and Polyolefin Adhesive: Comply with MIL-A-24179, Type II, Class I. Provide product recognized under UL 94 and listed in FM APP GUIDE. 2.2.3 Caulking
ASTM C 920, Type S, Grade NS, Class 25, Use A. 2.2.4 2.2.4.1 Corner Angles General
Nominal 0.016 inch aluminum 1 by 1 inch with factory applied kraft backing. Aluminum shall be ASTM B 209, Alloy 3003, 3105, or 5005. 2.2.4.2 Fittings
Fabricated Fittings are the prefabricated fittings for flexible elastomeric pipe insulation systems. Together with the flexible elastomeric tubes, they provide complete system integrity for retarding heat gain and controlling condensation drip from chilled-water and refrigeration systems. Flexible elastomeric, fabricated fittings provide thermal protection (0.25 k) and condensation resistance (0.05 Water Vapor Transmission factor). SECTION 23 07 00 Page 7
123044
2.2.5
Finishing Cement
ASTM C 449: Mineral fiber hydraulic-setting thermal insulating and finishing cement. All cements that may come in contact with Austenitic stainless steel must comply with ASTM C 795. 2.2.6 Fibrous Glass Cloth and Glass Tape
Fibrous glass cloth, with 20X20 maximum mesh size, and glass tape shall have maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E 84. Tape shall be 4 inch wide rolls. Class 3 tape shall be 4.5 ounces/square yard. Elastomeric Foam Tape: Black vapor-retarder foam tape with acrylic adhesive containing an anti-microbial additive. 2.2.7 Staples
Outward clinching type [monel] [ASTM A167, Type 304 or 316 stainless steel]. 2.2.8 2.2.8.1 Jackets Aluminum Jackets
Aluminum jackets shall be corrugated, embossed or smooth sheet, 0.016 inch nominal thickness; ASTM B 209, Temper H14, Temper H16, Alloy 3003, 5005, or 3105. Corrugated aluminum jacket shall not be used outdoors. Aluminum jacket securing bands shall be Type 304 stainless steel, 0.015 inch thick, 1/2 inch wide for pipe under 12 inch diameter and 3/4 inch wide for pipe over 12 inch and larger diameter. Aluminum jacket circumferential seam bands shall be 2 by 0.016 inch aluminum matching jacket material. Bands for insulation below ground shall be 3/4 by 0.020 inch thick stainless steel, or fiberglass reinforced tape. The jacket may, at the option of the Contractor, be provided with a factory fabricated Pittsburgh or "Z" type longitudinal joint. When the "Z" joint is used, the bands at the circumferential joints shall be designed by the manufacturer to seal the joints and hold the jacket in place. 2.2.8.2 Polyvinyl Chloride (PVC) Jackets
Polyvinyl chloride (PVC) jacket and fitting covers shall have high impact strength, UV resistant rating or treatment and moderate chemical resistance with minimum thickness 0.030 inch. 2.2.8.3 Vapor Barrier/Weatherproofing Jacket
Vapor barrier/weatherproofing jacket shall be laminated self-adhesive, greater than 3 plies standard grade, silver, white, black and embossed or greater than 8 ply (minimum 2.9 mils adhesive); with 0.0000 permeability when tested in accordance with ASTM E 96/E 96M; heavy duty, white or natural; and UV resistant. Flexible Elastomeric exterior foam with factory applied, UV Jacket made with a cold weather acrylic adhesive. Construction of laminate designed to provide UV resistance, high puncture, tear resistance and excellent WVT. 2.2.9 Vapor Retarder Required
ASTM C 921, Type I, minimum puncture resistance 50 Beach units on all surfaces except concealed ductwork, where a minimum puncture resistance of SECTION 23 07 00 Page 8
123044
25 Beach units is acceptable. Minimum tensile strength, 35 pounds/inch width. ASTM C 921, Type II, minimum puncture resistance 25 Beach units, tensile strength minimum 20 pounds/inch width. Jackets used on insulation exposed in finished areas shall have white finish suitable for painting without sizing. Based on the application, insulation materials that require factory applied jackets are mineral fiber, cellular glass, polyisocyanurate, and phenolic foam. Insulation materials that do not require jacketing are flexible elastomerics. All non-metallic jackets shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E 84. 2.2.9.1 White Vapor Retarder All Service Jacket (ASJ)
Standard reinforced fire retardant jacket for use on hot/cold pipes, ducts, or equipment. Vapor retarder jackets used on insulation exposed in finished areas shall have white finish suitable for painting without sizing. 2.2.9.2 Vapor Retarder/Vapor Barrier Mastic Coatings
a. The vapor barrier shall be self adhesive (minimum 2 mils adhesive, 3 mils embossed) greater than 3 plies standard grade, silver, white, black and embossed white jacket for use on hot/cold pipes. Less than 0.02 permeability when tested in accordance with ASTM E 96/E 96M. Meeting UL 723 or ASTM E 84 flame and smoke requirements; UV resistant. b. The vapor retarder coating shall be fire and water resistant and appropriately selected for either outdoor or indoor service. Color shall be white. The water vapor permeance of the compound shall be determined according to procedure B of ASTM E 96/E 96M utilizing apparatus described in ASTM E 96/E 96M. The coating shall be a nonflammable, fire resistant type. All other application and service properties shall be in accordance with ASTM C 647. 2.2.9.3 Laminated Film Vapor Retarder
ASTM C 1136, Type I, maximum moisture vapor transmission 0.02 perms, minimum puncture resistance 50 Beach units on all surfaces except concealed ductwork, where Type II, maximum moisture vapor transmission 0.02 perms, a minimum puncture resistance of 25 Beach units is acceptable. Vapor retarder shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E 84. Flexible Elastomeric exterior foam with factory applied UV Jacket. Construction of laminate designed to provide UV resistance, high puncture, tear resistance and excellent WVT. 2.2.9.4 Polyvinylidene Chloride (PVDC) Film Vapor Retarder
The PVDC film vapor retarder shall have a maximum moisture vapor transmission of 0.02 perms, minimum puncture resistance of 150 Beach units, a minimum tensile strength in any direction of 30 lb/inch when tested in accordance with ASTM D 882, and a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E 84. 2.2.9.5 Polyvinylidene Chloride Vapor Retarder Adhesive Tape
Requirements must meet the same as specified for Laminated Film Vapor Retarder above.
SECTION 23 07 00
Page 9
123044
2.2.9.6
Vapor Barrier
The vapor barrier shall be greater than 3 ply self adhesive laminate -white vapor barrier jacket- superior performance (less than 0.0000 permeability when tested in accordance with ASTM E 96/E 96M). Vapor barrier shall meet UL 723 or ASTM E 84 25 flame and 50 smoke requirements; and UV resistant. Minimum burst strength 185 psi in accordance with [TAPPI T403 OM] [ISO 2758]. Tensile strength 68 lb/inch width (PSTC-1000). Tape shall be as specified for laminated film vapor barrier above. 2.2.10 Vapor Retarder Not Required
ASTM C 921, Type II, Class D, minimum puncture resistance 50 Beach units on all surfaces except ductwork, where Type IV, maximum moisture vapor transmission 0.10, a minimum puncture resistance of 25 Beach units is acceptable. Jacket shall have a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E 84. 2.2.11 Wire
Soft annealed ASTM A580/A580M Type 302, 304 or 316 stainless steel, 16 or 18 gauge. 2.2.12 Insulation Bands
Insulation bands shall be 1/2 inch wide; 26 gauge stainless steel. 2.2.13 Sealants
Sealants shall be chosen from the butyl polymer type, the styrene-butadiene rubber type, or the butyl type of sealants. Sealants shall have a maximum moisture vapor transmission of 0.02 perms, and a maximum flame spread index of 25 and a maximum smoke developed index of 50 when tested in accordance with ASTM E 84. 2.3 PIPE INSULATION SYSTEMS
Insulation materials shall conform to Table 1. Insulation thickness shall be as listed in Table 2 and meet or exceed the requirements of [ ASHRAE 90.1 - IP][ASHRAE 90.2]. Insulation thickness shall be [1/2][1][__] inch. Comply with EPA requirements in accordance with Section 01 62 35 RECYCLED / RECOVERED MATERIALS. Pipe insulation materials shall be limited to those listed herein and shall meet the following requirements: 2.3.1 Aboveground Cold Pipeline ( -30 to 60 deg. F)
Insulation for outdoor, indoor, exposed or concealed applications, shall be as follows: a. Cellular Glass: ASTM C 552, Type II, and Type III. Supply the insulation with manufacturer's recommended factory-applied jacket/vapor barrier. b. Flexible Elastomeric Cellular Insulation: ASTM C 534/C 534M, Grade 1, Type I or II. Type II shall have vapor retarder/vapor barrier skin on one or both sides of the insulation. c. Phenolic Insulation: ASTM C 1126, Type III. Phenolic insulations shall comply with ASTM C 795 and with the ASTM C 665 paragraph SECTION 23 07 00 Page 10
123044
Corrosiveness. Supply the insulation with manufacturer's recommended factory-applied jacket/vapor barrier. dc. Polyisocyanurate Insulation: ASTM C 591, type I. Supply the insulation with manufacturer's recommended factory-applied vapor retarder/vapor barrier. Insulation with pre-applied adhesive shall not be used. e. Flexible Polyolefin Cellular Insulation: ASTM C 1427, Grade 1 Type I or II. f. Mineral Fiber Insulation with Integral Wicking Material (MFIWM): ASTM C 547. Install in accordance with manufacturer's instructions. 2.3.2 Aboveground Hot Pipeline (Above 60 deg. F)
Insulation for outdoor, indoor, exposed or concealed applications shall meet the following requirements. Supply the insulation with manufacturer's recommended factory-applied jacket/vapor barrier. a. Mineral Fiber: ASTM C 547, Types I, II or III, supply the insulation with manufacturer's recommended factory-applied jacket. b. Calcium Silicate: ASTM C 533, Type I indoor only, or outdoors above 250 degrees F pipe temperature. Supply insulation with the manufacturer's recommended factory-applied jacket/vapor barrier. c. Cellular Glass: ASTM C 552, Type II and Type III. Supply the insulation with manufacturer's recommended factory-applied jacket. d. Flexible Elastomeric Cellular Insulation: 1, Type I or II to 220 degrees F service. ASTM C 534/C 534M, Grade
e. Phenolic Insulation: ASTM C 1126 Type III to 250 degrees F service shall comply with ASTM C 795. Supply the insulation with manufacturer's recommended factory-applied jacket/vapor barrier. f. Perlite Insulation: ASTM C 610
g. Polyisocyanurate Insulation: ASTM C 591, Type 1, to 300 degrees F service. Supply the insulation with manufacturer's recommended factory applied jacket/vapor barrier.
h. Flexible Polyolefin Cellular Insulation: ASTM C 1427, Grade 1 Type I or II to 200 degrees F. 2.3.3 Above Ground Dual Temperature Pipeline
Selection of insulation for use over a dual temperature pipeline system (Outdoors, Indoor - Exposed or Concealed) shall be in accordance with the most limiting/restrictive case. Find an allowable material from paragraph PIPE INSULATION MATERIALS and determine the required thickness from the most restrictive case. Use the thickness listed in paragraphs INSULATION THICKNESS for cold & hot pipe applications. 2.3.4 Below-ground Pipeline Insulation
For below-ground pipeline insulation the following requirements shall be SECTION 23 07 00 Page 11
123044
met. 2.3.4.1 Cellular Glass
ASTM C 552, type II. 2.3.4.2 Polyisocyanurate
ASTM C 591, Type 1, to 300 degrees F.
2.4 2.4.1
DUCT INSULATION SYSTEMS Duct Insulation
Provide factory-applied [cellular glass polyisocyanurate or phenolic foam ][elastomeric insulation. Provide factory applied elastomeric closed cell or phenolic foam insulation according to manufacturer's recommendations for] insulation with insulation manufacturer's standard reinforced fire-retardant vapor barrier [, with identification of installed thermal resistance (R) value and out-of-package R value.] 2.4.1.1 Rigid Insulation
Rigid mineral fiber in accordance with ASTM C 612, Class 2 (maximum surface temperature 400 degrees F), 3 pcf average, 1-1/2 inch thick, Type IA, IB, II, III, and IV. [Alternately, minimum thickness may be calculated in accordance with [ASHRAE 90.2][ASHRAE 90.1 - IP].] 2.4.1.2 Blanket Insulation
Blanket flexible mineral fiber insulation conforming to ASTM C 553, Type 1, Class B-3, 3/4 pcf nominal, 2.0 inches thick or Type II up to 250 degrees F. Also ASTM C 1290 Type III may be used. [Alternately, minimum thickness may be calculated in accordance with [ASHRAE 90.2][ASHRAE 90.1 - IP].] 2.4.2 Kitchen Exhaust Ductwork Insulation
Insulation thickness shall be a minimum of 2 inches, blocks or boards, either mineral fiber conforming to ASTM C 612, Class 5, 20 pcf average [or calcium silicate conforming to ASTM C 533, Type II. Provide vapor barrier for outside air connection to kitchen exhaust hood]. The enclosure materials and the grease duct enclosure systems shall meet testing requirements of ASTM E2336 for noncombustibility, fire resistance, durability, internal fire, and fire-engulfment with a through-penetration fire stop. 2.4.3 2.4.3.1 Acoustical Duct Lining General
For ductwork indicated or specified in Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEM to be acoustically lined, provide external insulation in accordance with this specification section and in addition to the acoustical duct lining. Do not use acoustical lining in place of duct wrap or rigid board insulation (insulation on the exterior of the duct).
SECTION 23 07 00
Page 12
123044
2.4.3.2
Duct Liner
Flexible Elastomeric Acoustical and Conformable Duct Liner: Materials: Flexible Elastomeric Thermal, Acoustical and Conformable Insulation Compliance with ASTM C 534/C 534M Grade 1, Type II or ASTM C 1534 and NFPA 90A or NFPA 90B. 2.4.2 2.4.2.1 Duct Insulation Jackets All-Purpose Jacket
Provide insulation with insulation manufacturer's standard reinforced fire-retardant jacket with or without integral vapor barrier as required by the service. In exposed locations, provide jacket with a white surface suitable for field painting. 2.4.2.2 Metal Jackets
a. Aluminum Jackets: ASTM B 209, Temper H14, minimum thickness of 27 gauge ( 0.016 inch), with factory-applied polyethylene and kraft paper moisture barrier on inside surface. Provide smooth surface jackets for jacket outside dimension 8 inches and larger. Provide corrugated surface jackets for jacket outside dimension 8 inches and larger. Provide stainless steel bands, minimum width of 1/2 inch. b. Stainless Steel Jackets: ASTM A167 or ASTM A240/A240M; Type 304, minimum thickness of 33 gauge ( 0.010 inch), smooth surface with factory-applied polyethylene and kraft paper moisture barrier on inside surface. Provide stainless steel bands, minimum width of 1/2 inch. 2.4.2.3 Vapor Barrier/Weatherproofing Jacket
Vapor barrier/weatherproofing jacket shall be laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) less than 0.0000 permeability, (greater than 3 ply, standard grade, silver, white, black and embossed or greater than 8 ply (minimum 2.9 mils adhesive), heavy duty white or natural). 2.4.3 Weatherproof Duct Insulation
Provide rigid glass fiber board [ASTM C 591 Type I, polyurethane or polyisocyanate board insulation, minimum density of 1.7 pcf] [ASTM C 552, cellular glass thermal insulation 4 inch thick, 3 pound per cubic foot density.] [ASTM C 534/C 534M Grade 1, Type II, flexible elastomeric cellular insulation], and weatherproofing as specified in manufacturer's instruction. Multi-ply, Polymeric Blend Laminate Jacketing: Construction of laminate designed to provide UV resistance, high puncture, tear resistance and excellent WVT. 2.5 EQUIPMENT INSULATION SYSTEMS
Insulate equipment and accessories as specified in Tables 4 and 5. In outside locations, provide insulation 1/2 inch thicker than specified. Increase the specified insulation thickness for equipment where necessary to equal the thickness of angles or other structural members to make a smooth, exterior surface.
SECTION 23 07 00
Page 13
123044
PART 3 3.1
EXECUTION APPLICATION - GENERAL
Insulation shall only be applied to unheated and uncooled piping and equipment. Flexible elastomeric cellular insulation shall not be compressed at joists, studs, columns, ducts, hangers, etc. The insulation shall not pull apart after a one hour period; any insulation found to pull apart after one hour, shall be replaced. 3.1.1 Installation
Except as otherwise specified, material shall be installed in accordance with the manufacturer's written instructions. Insulation materials shall not be applied until [tests] [tests and heat tracing] specified in other sections of this specification are completed. Material such as rust, scale, dirt and moisture shall be removed from surfaces to receive insulation. Insulation shall be kept clean and dry. Insulation shall not be removed from its shipping containers until the day it is ready to use and shall be returned to like containers or equally protected from dirt and moisture at the end of each workday. Insulation that becomes dirty shall be thoroughly cleaned prior to use. If insulation becomes wet or if cleaning does not restore the surfaces to like new condition, the insulation will be rejected, and shall be immediately removed from the jobsite. Joints shall be staggered on multi layer insulation. Mineral fiber thermal insulating cement shall be mixed with demineralized water when used on stainless steel surfaces. Insulation, jacketing and accessories shall be installed in accordance with MICA Insulation Stds plates except where modified herein or on the drawings. 3.1.2 Firestopping
Where pipes and ducts pass through fire walls, fire partitions, above grade floors, and fire rated chase walls, the penetration shall be sealed with fire stopping materials as specified in Section 07 84 00 FIRESTOPPING. The protection of ducts at point of passage through firewalls must be in accordance with NFPA 90A and/or NFPA 90B. All other penetrations, such as piping, conduit, and wiring, through firewalls must be protected with a material or system of the same hourly rating that is listed by UL, FM, or a NRTL. 3.1.3 Painting and Finishing
Painting shall be as specified in Section 09 90 00 PAINTS AND COATINGS. 3.1.4 Installation of Flexible Elastomeric Cellular Insulation
Flexible elastomeric cellular insulation shall be installed with seams and joints sealed with rubberized contact adhesive. Flexible elastomeric cellular insulation shall not be used on surfaces greater than 220 degrees F. Seams shall be staggered when applying multiple layers of insulation. Insulation exposed to weather and not shown to have jacketing shall be protected with two coats of UV resistant finish or PVC or metal jacketing as recommended by the manufacturer after the adhesive is dry and cured. A brush coating of adhesive shall be applied to both butt ends to be joined and to both slit surfaces to be sealed. The adhesive shall be allowed to set until dry to touch but tacky under slight pressure before joining the surfaces. Insulation seals at seams and joints shall not be capable of being pulled apart one hour after application. Insulation that can be SECTION 23 07 00 Page 14
123044
pulled apart one hour after installation shall be replaced. 3.1.5 Welding
No welding shall be done on piping, duct or equipment without written approval of the Contracting Officer. The capacitor discharge welding process may be used for securing metal fasteners to duct. 3.1.6 Pipes/Ducts/Equipment which Require Insulation
Insulation is required on all pipes, ducts, or equipment, except for omitted items, as specified. 3.2 PIPE INSULATION SYSTEMS INSTALLATION
3.2.1 3.2.1.1
Pipe Insulation General
Pipe insulation shall be installed on aboveground hot and cold pipeline systems as specified below to form a continuous thermal retarder/barrier, including straight runs, fittings and appurtenances unless specified otherwise. Installation shall be with full length units of insulation and using a single cut piece to complete a run. Cut pieces or scraps abutting each other shall not be used. Pipe insulation shall be omitted on the following: a. Pipe used solely for fire protection.
b. Chromium plated pipe to plumbing fixtures. However, fixtures for use by the physically handicapped shall have the hot water supply and drain, including the trap, insulated where exposed. c. d. e. f. g. h. 3.2.1.2 a. Sanitary drain lines. Air chambers. Adjacent insulation. ASME stamps. Access plates of fan housings. Cleanouts or handholes. Pipes Passing Through Walls, Roofs, and Floors Pipe insulation shall be continuous through the sleeve.
b. An aluminum jacket or vapor barrier/weatherproofing - self adhesive jacket (minimum 2 mils adhesive, 3 mils embossed) less than 0.0000 permeability, greater than 3 ply standard grade, silver, white, black and embossed with factory applied moisture retarder shall be provided over the insulation wherever penetrations require sealing. c. Where pipes penetrate interior walls, the aluminum jacket or vapor barrier/weatherproofing - self adhesive jacket (minimum 2 mils adhesive, 3 mils embossed) less than 0.0000 permeability, greater than SECTION 23 07 00 Page 15
123044
3 plies standard grade, silver, white, black and embossed shall extend 2 inches beyond either side of the wall and shall be secured on each end with a band. d. Where penetrating floors, the aluminum jacket shall extend from a point below the backup material to a point 10 inches above the floor with one band at the floor and one not more than 1 inch from the end of the aluminum jacket. e. Where penetrating waterproofed floors, the aluminum jacket shall extend from below the backup material to a point 2 inches above the flashing with a band 1 inch from the end of the aluminum jacket. f. Where penetrating exterior walls, the aluminum jacket required for pipe exposed to weather shall continue through the sleeve to a point 2 inches beyond the interior surface of the wall. g. Where penetrating roofs, pipe shall be insulated as required for interior service to a point flush with the top of the flashing and sealed with vapor retarder coating. The insulation for exterior application shall butt tightly to the top of flashing and interior insulation. The exterior aluminum jacket shall extend 2 inches down beyond the end of the insulation to form a counter flashing. The flashing and counter flashing shall be sealed underneath with caulking. h. For hot water pipes supplying lavatories or other similar heated service that requires insulation, the insulation shall be terminated on the backside of the finished wall. The insulation termination shall be protected with two coats of vapor barrier coating with a minimum total thickness of 1/16 inch applied with glass tape embedded between coats (if applicable). The coating shall extend out onto the insulation 2 inches and shall seal the end of the insulation. Glass tape seams shall overlap 1 inch. The annular space between the pipe and wall penetration shall be caulked with approved fire stop material. The pipe and wall penetration shall be covered with a properly sized (well fitting) escutcheon plate. The escutcheon plate shall overlap the wall penetration at least 3/8 inches. i. For domestic cold water pipes supplying lavatories or other similar cooling service that requires insulation, the insulation shall be terminated on the finished side of the wall (i.e., insulation must cover the pipe throughout the wall penetration). The insulation shall be protected with two coats of vapor barrier coating with a minimum total thickness of 1/16 inch. The coating shall extend out onto the insulation 2 inches and shall seal the end of the insulation. The annular space between the outer surface of the pipe insulation and the wall penetration shall be caulked with an approved fire stop material having vapor retarder properties. The pipe and wall penetration shall be covered with a properly sized (well fitting) escutcheon plate. The escutcheon plate shall overlap the wall penetration by at least 3/8 inches. 3.2.1.3 Pipes Passing Through Hangers
a. Insulation, whether hot or cold application, shall be continuous through hangers. All horizontal pipes 2 inches and smaller shall be supported on hangers with the addition of a Type 40 protection shield to protect the insulation in accordance with MSS SP-69. Whenever insulation shows signs of being compressed, or when the insulation or SECTION 23 07 00 Page 16
123044
jacket shows visible signs of distortion at or near the support shield, insulation inserts as specified below for piping larger than 2 inches shall be installed, or factory insulated hangers (designed with a load bearing core) can be used. b. Horizontal pipes larger than 2 inches at 60 degrees F and above shall be supported on hangers in accordance with MSS SP-69, and Section 22 00 00 PLUMBING, GENERAL PURPOSE. c. Horizontal pipes larger than 2 inches and below 60 degrees F shall be supported on hangers with the addition of a Type 40 protection shield in accordance with MSS SP-69. An insulation insert of cellular glass, prefabricated insulation pipe hangers, perlite above 80 degrees F ), or the necessary strength polyisocyanurate shall be installed above each shield. The insert shall cover not less than the bottom 180-degree arc of the pipe. Inserts shall be the same thickness as the insulation, and shall extend 2 inches on each end beyond the protection shield. When insulation inserts are required in accordance with the above, and the insulation thickness is less than 1 inch, wooden or cork dowels or blocks may be installed between the pipe and the shield to prevent the weight of the pipe from crushing the insulation, as an option to installing insulation inserts. The insulation jacket shall be continuous over the wooden dowel, wooden block, or insulation insert. d. Vertical pipes shall be supported with either Type 8 or Type 42 riser clamps with the addition of two Type 40 protection shields in accordance with MSS SP-69 covering the 360-degree arc of the insulation. An insulation insert of cellular glass or calcium silicate shall be installed between each shield and the pipe. The insert shall cover the 360-degree arc of the pipe. Inserts shall be the same thickness as the insulation, and shall extend 2 inches on each end beyond the protection shield. When insulation inserts are required in accordance with the above, and the insulation thickness is less than 1 inch, wooden or cork dowels or blocks may be installed between the pipe and the shield to prevent the hanger from crushing the insulation, as an option instead of installing insulation inserts. The insulation jacket shall be continuous over the wooden dowel, wooden block, or insulation insert. The vertical weight of the pipe shall be supported with hangers located in a horizontal section of the pipe. When the pipe riser is longer than 30 feet, the weight of the pipe shall be additionally supported with hangers in the vertical run of the pipe that are directly clamped to the pipe, penetrating the pipe insulation. These hangers shall be insulated and the insulation jacket sealed as indicated herein for anchors in a similar service. e. Inserts shall be covered with a jacket material of the same appearance and quality as the adjoining pipe insulation jacket, shall overlap the adjoining pipe jacket 1-1/2 inches, and shall be sealed as required for the pipe jacket. The jacket material used to cover inserts in flexible elastomeric cellular insulation shall conform to ASTM C 1136, Type 1, and is allowed to be of a different material than the adjoining insulation material. 3.2.1.4 Flexible Elastomeric Cellular Pipe Insulation
Flexible elastomeric cellular pipe insulation shall be tubular form for pipe sizes 6 inches and less. Grade 1, Type II sheet insulation used on pipes larger than 6 inches shall not be stretched around the pipe. On pipes larger than 12 inches, the insulation shall be adhered directly to SECTION 23 07 00 Page 17
123044
the pipe on the lower 1/3 of the pipe. Seams shall be staggered when applying multiple layers of insulation. Sweat fittings shall be insulated with miter-cut pieces the same size as on adjacent piping. Screwed fittings shall be insulated with sleeved fitting covers fabricated from miter-cut pieces and shall be overlapped and sealed to the adjacent pipe insulation. 3.2.1.5 Pipes in high abuse areas.
In high abuse areas such as janitor closets and traffic areas in equipment rooms, kitchens, and mechanical rooms, [welded PVC] [stainless steel], aluminum or flexible laminate cladding (comprised of elastomeric, plastic or metal foil laminate) laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket, - less than 0.0000 permeability; (greater than 3 ply, standard grade, silver, white, black and embossed) [aluminum] jackets shall be utilized. Pipe insulation to the 6 foot level shall be protected. [Other areas that specifically require protection to the 6 foot level are [_____].] 3.2.1.6 Pipe Insulation Material and Thickness
TABLE 1 Insulation Material For Piping (F) __________________________________________________________________________ Service Material Spec-Type-Class Vapor Retard/ Vapor Barr'r Required ___________________________________________________________________________ Chilled Water Cellular Glass ASTM C 552 II 2 NoYes (Supply & Flex Elast Cell'r ASTM C 534/C 534M I No Return, Dual Faced Phenol Foam ASTM C 1126 III Yes Temperature Polyisocyanurate ASTM C 591 I Yes Piping, 40F [Mineral Fiber with nominal) Wicking Material ASTM C 547 I Yes] ___________________________________________________________________________ Heating Hot Mineral Fiber ASTM C 547 I 1 No Water Supply & Calcium Silicate ASTM C 533 I No Return, Heated Cellular Glass ASTM C 552 II 2 YesNo Oil Faced Phenol Foam ASTM C 1126 III Yes (Max 250F) Perlite ASTM C 610 No Polyisocyanurate ASTM C 591 I No Flex Elast Cell'r ASTM C 534/C 534M I 2 No _____________________________________________________________________________ Cold Domestic Polyisocyanurate ASTM C 591 I Yes Water Piping, Cellular Glass ASTM C 552 II 2 No Makeup Water & Flex Elast Cell'r ASTM C 534/C 534M I No Drinking Fount Faced Phenol Foam ASTM C 1126 III Yes Drain Piping Polyofin Clos'cell ASTM C 1427 I No ___________________________________________________________________________ Hot Domestic Mineral Fiber ASTM C 547 I 1 YesNo Water Supply & Cellular Glass ASTM C 552 II 2 No Recirculating Flex Elast Cell'r ASTM C 534/C 534M I No Piping (Max. Faced Phenol Foam ASTM C 1126 III Yes 200F) Polyisocyanurate ASTM C 591 I No ___________________________________________________________________________ Refrigerant Flex Elast Cell'r ASTM C 534/C 534M I YesNo SECTION 23 07 00 Page 18
123044
TABLE 1 Insulation Material For Piping (F) __________________________________________________________________________ Service Material Spec-Type-Class Vapor Retard/ Vapor Barr'r Required ___________________________________________________________________________ Suction Piping Cellular Glass ASTM C 552 II 1 Yes (35F nominal) Faced Phenol Foam ASTM C 1126 III Yes Polyisocyanurate ASTM C 591 I Yes ___________________________________________________________________________ Compressed Air Cellular Glass ASTM C 552 II No Discharge, Mineral Fiber ASTM C 547 I 1 No Steam and Calcium Silicate ASTM C 533 I No Condensate Faced Phenol Foam ASTM C 1126 III Yes Return Perlite ASTM C 610 No (201 to 250F) Polyisocyanurate ASTM C 591 I No Flex Elast Cell'r ASTM C 534/C 534M I 2 No ___________________________________________________________________________ Exposed Lav'ry Flex Elast Cell'r ASTM C 534/C 534M I No Drains, Expo'd Polyofin Clos'cell ASTM C 1427 I No Domestic Water Piping & Drains to Areas for Handicap Personnel ___________________________________________________________________________ Horizontal Roof Polyisocyanurate ASTM C 591 I Yes Drain Leaders Flex Elast Cell'r ASTM C 534/C 534M I No (Including Faced Phenol Foam ASTM C 1126 III Yes Underside of Cellular Glass ASTM C 552 III Yes Roof Drain Fittings) ___________________________________________________________________________ A/C condensate Polyisocyanurate ASTM C 591 I Yes Drain Located Cellular Glass ASTM C 552 II 2 No Inside Bldg. Flex Elast Cell'r ASTM C 534/C 534M I No Faced Phenol Foam ASTM C 1126 II Yes ___________________________________________________________________________ Medium Tempera- Mineral Fiber ASTM C 547 I 1 No ture Hot Water, Calcium Silicate ASTM C 533 I No Steam and Cellular Glass ASTM C 552 I or II No Condensate Perlite ASTM C 610 No (251 to 350F) polyisocyanurate ASTM C 591 I No ___________________________________________________________________________ High TemperaMineral Fiber ASTM C 547 I 2 No ture Hot Water Calcium Silicate ASTM C 533 I No & Steam (351 Perlite ASTM C 610 No to 700F) Cellular Glass ASTM C 552 No Polyisocyanurate ASTM C 591 I No __________________________________________________________________________ Brine Systems Cellular Glass ASTM C 552 II 2 No Cryogenics Flex Elast Cell'r ASTM C 534/C 534M I No (Minus 30 Faced Phenol Foam ASTM C 1126 III Yes to 0F) Polyisocyanurate ASTM C 591 I Yes ___________________________________________________________________________ Brine Systems Cellular Glass ASTM C 552 II 2 No Cryogenics Flex Elast Cell'r ASTM C 534/C 534M I No SECTION 23 07 00 Page 19
123044
TABLE 1 Insulation Material For Piping (F) __________________________________________________________________________ Service Material Spec-Type-Class Vapor Retard/ Vapor Barr'r Required ___________________________________________________________________________ (Zero to 34F) Faced Phenol Foam ASTM C 1126 III Yes Polyisocyanurate ASTM C 591 I Yes ___________________________________________________________________________ TABLE 2 Piping Insulation Thickness (inch and F) _______________________________________________________________________________ Tube And Pipe Size (Inches) >or = to 8 _______________________________________________________________________________ [Chilled Water (Supply & Return, & Dual Temperature Piping) (40F Nominal)] Cellular Glass 1.5 Faced Phenol Foam 1 Polyisocyanurate 1 [Mineral Fiber with Wicking Material 1 Flex Elast Cell'r 1 2 1 1 1.5 1 2 1 1 1.5 1 2.5 1.5 1 2 N/A 3 1.5 1 2] N/A Service Material <1 1- <1.5 1.5- <4 4- <8
[Chilled Water Cellular Glass 1.5 1.5 1.5 1.5 2 (Supply & Flex Elas Cell'r 1 1 1 N/A N/A Return, & Dual Faced Phenol Foam 1 1 1 1 1.5 Temperature [Mineral Fiber with Piping) (40F Wicking Material 1 1.5 1.5 2 2] Nominal)] ___________________________________________________________________________ Heating Hot Water Mineral Fiber 1.5 1.5 2 2 2 Supply & Return, Calcium Silicate 2.5 2.5 3 3 3 Heated Oil (Max. Cellular Glass 2 2 5 3 3 3 250F) Perlite 2.5 2.5 3 3 3 Polyisocyanurate 1 1 1.5 1.5 1.5 Flex Elast Cell'r 1 1 1 N/A N/A ___________________________________________________________________________ Cold Domestic Cellular Glass 1.5 1.5 1.5 1.5 1.5 Water Piping, Flex Elas Cell'r 1 1 1 N/A N/A Makeup Water, & Faced Phenol Foam 1 1 1 1 1 Drinking Fountain Polyisocyanurate 1 1 1 1 1 Drain Piping ___________________________________________________________________________ Hot Domestic Mineral Fiber 1 1 1 1.5 1.5 Water Supply and Cellular Glass 1.5 1.5 1.5 2 2 Recirculating Flex Elas Cell'r 1 1 1 N/A N/A Piping (Max 200F) Polyisocyanurate 1 1 1 1 1.5 _____________________________________________________________________________ Refrigerant Flex Elas Cell'r 0.5 0.5 1 N/A N/A Suction Piping Cellular Glass 1.5 1.5 1.5 1.5 1.5 (35F nominal) Faced Phenol Foam 1 1 1 1 1 Polyisocyanurate 1 1 1 1 1 _________________________________________________________________________ SECTION 23 07 00 Page 20
123044
TABLE 2 Piping Insulation Thickness (inch and F) _______________________________________________________________________________ Tube And Pipe Size (Inches) >or = to 8 _______________________________________________________________________________ Compressed Air Mineral Fiber 1.5 1.5 2 2 2 Discharge, 1.5* 2* 2.5* 3* 3.5* Steam, and Calcium Silicate 2.5 3 4 4 4.5 Condensate Return Cellular Glass 2 2.5 3 3 3 (201F to 250F) Perlite 2.5 3 4 4 4.5 Polyisocyanurate 1.5 1.5 2 2 2 Flwx Elast Cell'r 1 1 1 N/A N/A _____________________________________________________________________________ Exposed Lavatory Flex Elas Cell'r 0.5 0.5 0.5 0.5 0.5 Drains, Exposed Domestic Water Piping & Drains to Areas for Handicap Personnel ___________________________________________________________________________ Horizontal Roof Cellular Glass 1.5 1.5 1.5 1.5 1.5 Drain Leaders Flex Elas Cell'r 1 1 1 1 1 (including Faced Phenol Foam 1 1 1 1 1 Underside of Roof Polyisocyanurate 1 1 1 1 1 Drain Fitting) _____________________________________________________________________________ A/C condensate Cellular Glass 1.5 1.5 1.5 1.5 1.5 Drain Located Flex Elas Cell'r 1 1 1 N/A N/A Inside Bldg. Faced Phenol Foam 1 1 1 1 1 ___________________________________________________________________________ Medium TempMineral Fiber 1.5 3 3 4 4 erature Hot Water 2.5* 3.5* and Steam Calcium Silicate 2.5 3.5 4.5 4.5 5 (251F to 350F) Perlite 2.5 3.5 4.5 4.5 5 ___________________________________________________________________________ High Temperature Mineral Fiber 2.5 3 3 4 4 Water (351F to Calcium Silicate 4 4.5 6 6 6 400F) and Steam Perlite 4 4.5 6 6 6 (351F to 500F) Polyisocyanurate 1 1 1 1 1 ___________________________________________________________________________ Brine Systems Cellular Glass 2.5 2.5 3 3 3.5 Cryogenics Flex Elas Cell'r 1 1 N/A N/A N/A (Minus 30 to Faced Phenol Foam 1.5 1.5 2 2 2 ZeroF) Polyisocyanurate 1.5 1.5 2 2 2 __________________________________________________________________________ Brine Systems, Cellular Glass 2 2 2 2.5 3 Cryogenics Flex Elas Cell'r 1 1 1 N/A N/A (Zero to 34F) Faced Phenol Foam 1 1 1 1.5 1.5 Polyisocyanurate 1 1 1 1.5 1.5 _____________________________________________________________________________ 3.2.2 Aboveground Cold Pipelines Service Material <1 1- <1.5 1.5- <4 4- <8
The following cold pipelines for minus 30 to plus 60 degrees F, shall be insulated in accordance with Table 2 except those piping listed in SECTION 23 07 00 Page 21
123044
subparagraph Pipe Insulation in PART 3 as to be omitted. is not limited to the following: a. b. c. dc. ed. f. ge. h. [Domestic cold and chilled drinking water.] Make-up water.
This includes but
Horizontal and vertical portions of interior roof drains. Refrigerant suction lines. Chilled water. Dual temperature water, i.e. HVAC hot/chilled water. Air conditioner condensate drains. Brine system cryogenics
if. Exposed lavatory drains and domestic water lines serving plumbing fixtures for handicap persons. 3.2.2.1 Insulation Material and Thickness
Insulation thickness for cold pipelines shall be determined using Table 2. 3.2.2.2 Factory or Field applied Jacket
Insulation shall be covered with a factory applied vapor retarder jacket/vapor barrier or field applied seal welded PVC jacket or greater than 3 ply laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket - less than 0.0000 permeability, standard grade, sliver, white, black and embossed for use with Mineral Fiber, Cellular Glass, Phenolic Foam, and Polyisocyanurate Foam Insulated Pipe. Insulation inside the building, to be protected with an aluminum jacket or greater than 3ply vapor barrier/weatherproofing self-adhesive (minimum 2 mils adhesive, 3 mils embossed) product, less than 0.0000 permeability, standard grade, Embossed Silver, White & Black, shall have the insulation and vapor retarder jacket installed as specified herein. The aluminum jacket or greater than 3ply vapor barrier/weatherproofing self-adhesive (minimum 2 mils adhesive, 3 mils embossed) product, less than 0.0000 permeability, standard grade, embossed silver, White & Black, shall be installed as specified for piping exposed to weather, except sealing of the laps of the aluminum jacket is not required. In high abuse areas such as janitor closets and traffic areas in equipment rooms, kitchens, and mechanical rooms, aluminum jackets or greater than 3ply vapor barrier/weatherproofing self-adhesive (minimum 2 mils adhesive, 3 mils embossed) product, less than 0.0000 permeability, standard grade, embossed silver, white & black, shall be provided for pipe insulation to the 6 ft level. Other areas that specifically require protection to the 6 ft level are [_____]. 3.2.2.3 Installing Insulation for Straight Runs Hot and Cold Pipe
a. Insulation shall be applied to the pipe with joints tightly butted. All butted joints and ends shall be sealed with joint sealant and sealed with a vapor retarder coating, greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape or PVDC adhesive tape.
SECTION 23 07 00
Page 22
123044
b. Longitudinal laps of the jacket material shall overlap not less than 1-1/2 inches. Butt strips 3 inches wide shall be provided for circumferential joints. c. Laps and butt strips shall be secured with adhesive and stapled on 4 inch centers if not factory self-sealing. If staples are used, they shall be sealed in accordance with item "e." below. Note that staples are not required with cellular glass systems. d. Factory self-sealing lap systems may be used when the ambient temperature is between 40 and 120 degrees F during installation. The lap system shall be installed in accordance with manufacturer's recommendations. Stapler shall be used only if specifically recommended by the manufacturer. Where gaps occur, the section shall be replaced or the gap repaired by applying adhesive under the lap and then stapling. e. All Staples, including those used to repair factory self-seal lap systems, shall be coated with a vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape. All seams, except those on factory self-seal systems shall be coated with vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape. f. Breaks and punctures in the jacket material shall be patched by wrapping a strip of jacket material around the pipe and securing it with adhesive, stapling, and coating with vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape. The patch shall extend not less than 1-1/2 inches past the break. g. At penetrations such as thermometers, the voids in the insulation shall be filled and sealed with vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape. h. Installation of flexible elastomeric cellular pipe insulation shall be by slitting the tubular sections and applying them onto the piping or tubing. Alternately, whenever possible slide un-slit sections over the open ends of piping or tubing. All seams and butt joints shall be secured and sealed with adhesive. When using self seal products only the butt joints shall be secured with adhesive. Insulation shall be pushed on the pipe, never pulled. Stretching of insulation may result in open seams and joints. All edges shall be clean cut. Rough or jagged edges of the insulation shall not be permitted. Proper tools such as sharp knives shall be used. Grade 1, Type II sheet insulation when used on pipe larger than 6 inches shall not be stretched around the pipe. On pipes larger than 12 inches, adhere sheet insulation directly to the pipe on the lower 1/3 of the pipe. 3.2.2.4 Insulation for Fittings and Accessories
a. Pipe insulation shall be tightly butted to the insulation of the fittings and accessories. The butted joints and ends shall be sealed with joint sealant and sealed with a vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape. SECTION 23 07 00 Page 23
123044
b. Precut or preformed insulation shall be placed around all fittings and accessories and shall conform to MICA plates except as modified herein: 5 for anchors; 10, 11, and 13 for fittings; 14 for valves; and 17 for flanges and unions. Insulation shall be the same insulation as the pipe insulation, including same density, thickness, and thermal conductivity. Where precut/preformed is unavailable, rigid preformed pipe insulation sections may be segmented into the shape required. Insulation of the same thickness and conductivity as the adjoining pipe insulation shall be used. If nesting size insulation is used, the insulation shall be overlapped 2 inches or one pipe diameter. Elbows insulated using segments shall conform to MICA Tables 12.20 "Mitered Insulation Elbow'. c. Upon completion of insulation installation on flanges, unions, valves, anchors, fittings and accessories, terminations, seams, joints and insulation not protected by factory vapor retarder jackets or PVC fitting covers shall be protected with PVDC or greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape or two coats of vapor retarder coating with a minimum total thickness of 1/16 inch, applied with glass tape embedded between coats. Tape seams shall overlap 1 inch. The coating shall extend out onto the adjoining pipe insulation 2 inches. Fabricated insulation with a factory vapor retarder jacket shall be protected with either greater than 3 ply laminate jacket - less than 0.0000 perm adhesive tape, standard grade, silver, white, black and embossed or PVDC adhesive tape or two coats of vapor retarder coating with a minimum thickness of 1/16 inch and with a 2 inch wide glass tape embedded between coats. Where fitting insulation butts to pipe insulation, the joints shall be sealed with a vapor retarder coating and a 4 inch wide ASJ tape which matches the jacket of the pipe insulation. d. Anchors attached directly to the pipe shall be insulated for a sufficient distance to prevent condensation but not less than 6 inches from the insulation surface. e. Insulation shall be marked showing the location of unions, strainers, and check valves. 3.2.2.5 Optional PVC Fitting Covers
At the option of the Contractor, premolded, one or two piece PVC fitting covers may be used in lieu of the vapor retarder and embedded glass tape. Factory precut or premolded insulation segments shall be used under the fitting covers for elbows. Insulation segments shall be the same insulation as the pipe insulation including same density, thickness, and thermal conductivity. The covers shall be secured by PVC vapor retarder tape, adhesive, seal welding or with tacks made for securing PVC covers. Seams in the cover, and tacks and laps to adjoining pipe insulation jacket, shall be sealed with vapor retarder tape to ensure that the assembly has a continuous vapor seal. 3.2.3 3.2.3.1 Aboveground Hot Pipelines General Requirements
All hot pipe lines above 60 degrees F, except those piping listed in subparagraph Pipe Insulation in PART 3 as to be omitted, shall be insulated in accordance with Table 2. This includes but is not limited to the SECTION 23 07 00 Page 24
123044
following: a. b. c. db. e. f. Domestic hot water supply & re-circulating system. Steam. Condensate & compressed air discharge. Hot water heating. Heated oil. Water defrost lines in refrigerated rooms.
Insulation shall be covered, in accordance with manufacturer's recommendations, with a factory applied Type I jacket or field applied aluminum where required or seal welded PVC. 3.2.3.2 Insulation for Fittings and Accessories
a. General. Pipe insulation shall be tightly butted to the insulation of the fittings and accessories. The butted joints and ends shall be sealed with joint sealant. Insulation shall be marked showing the location of unions, strainers, check valves and other components that would otherwise be hidden from view by the insulation. b. Precut or Preformed. Precut or preformed insulation shall be placed around all fittings and accessories. Insulation shall be the same insulation as the pipe insulation, including same density, thickness, and thermal conductivity. c. Rigid Preformed. Where precut/preformed is unavailable, rigid preformed pipe insulation sections may be segmented into the shape required. Insulation of the same thickness and conductivity as the adjoining pipe insulation shall be used. If nesting size insulation is used, the insulation shall be overlapped 2 inches or one pipe diameter. Elbows insulated using segments shall conform to MICA Tables 12.20 "Mitered Insulation Elbow". 3.2.4 Piping Exposed to Weather
Piping exposed to weather shall be insulated and covered with aluminumjacket ed as specified for the applicable service inside the building. After this procedure, aA laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket - less than 0.0000 permeability (greater than 3 ply, standard grade, silver, white, black and embossed aluminum jacket or PVC jacket shall be applied. PVC jacketing requires no factory-applied jacket beneath it, however an all service jacket shall be applied if factory applied jacketing is not furnished. Flexible elastomeric cellular insulation exposed to weather shall be treated in accordance with paragraph INSTALLATION OF FLEXIBLE ELASTOMERIC CELLULAR INSULATION in PART 3. 3.2.4.1 Aluminum Jacket
The jacket for hot piping may be factory applied. The jacket shall overlap not less than 2 inches at longitudinal and circumferential joints and shall be secured with bands at not more than 12 inch centers. Longitudinal joints shall be overlapped down to shed water and located at 4 or 8 o'clock SECTION 23 07 00 Page 25
123044
positions. Joints on piping 60 degrees F and below shall be sealed with caulking while overlapping to prevent moisture penetration. Where jacketing on piping 60 degrees F and below abuts an un-insulated surface, joints shall be caulked to prevent moisture penetration. Joints on piping above 60 degrees F shall be sealed with a moisture retarder. 3.2.4.2 Insulation for Fittings
Flanges, unions, valves, fittings, and accessories shall be insulated and finished as specified for the applicable service. Two coats of breather emulsion type weatherproof mastic (impermeable to water, permeable to air) recommended by the insulation manufacturer shall be applied with glass tape embedded between coats. Tape overlaps shall be not less than 1 inch and the adjoining aluminum jacket not less than 2 inches. Factory preformed aluminum jackets may be used in lieu of the above. Molded PVC fitting covers shall be provided when PVC jackets are used for straight runs of pipe. PVC fitting covers shall have adhesive welded joints and shall be weatherproof laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket - less than 0.0000 permeability, (greater than 3 ply, standard grade, silver, white, black and embossed, and UV resistant. 3.2.4.3 PVC Jacket
PVC jacket shall be ultraviolet resistant and adhesive welded weather tight with manufacturer's recommended adhesive. Installation shall include provision for thermal expansion. 3.2.5 Below Ground Pipe Insulation
Below ground pipes shall be insulated in accordance with Table 2, except as precluded in subparagraph Pipe Insulation in PART 3. This includes, but is not limited to the following: a. b. c. d. e. f. 3.2.5.1 Heated oil. Domestic hot water. Heating hot water. Dual temperature water. Steam. Condensate. Type of Insulation
Below ground pipe shall be insulated with Cellular Glass insulation, or with Polyisocyanurate insulation, in accordance with manufacturer's instructions for application with thickness as determined from Table 2 (whichever is the most restrictive). 3.2.5.2 Installation of Below ground Pipe Insulation
a. Bore surfaces of the insulation shall be coated with a thin coat of gypsum cement of a type recommended by the insulation manufacturer. Coating thickness shall be sufficient to fill surface cells of insulation. Mastic type materials shall not be used for this coating. SECTION 23 07 00 Page 26
123044
Note that unless this is for a cyclic application (i.e., one that fluctuates between high and low temperature on a daily process basis) there is no need to bore coat the material. b. Stainless steel bands, 3/4 inch wide by 0.020 inch thick shall be used to secure insulation in place. A minimum of two bands per section of insulation shall be applied. As an alternate, fiberglass reinforced tape may be used to secure insulation on piping up to 12 inches in diameter. A minimum of two bands per section of insulation shall be applied. c. Insulation shall terminate at anchor blocks but shall be continuous through sleeves and manholes. d. At point of entry to buildings, underground insulation shall be terminated 2 inches inside the wall or floor, shall butt tightly against the aboveground insulation and the butt joint shall be sealed with high temperature silicone sealant and covered with fibrous glass tape. e. Provision for expansion and contraction of the insulation system shall be made in accordance with the insulation manufacturer's recommendations. f. Flanges, couplings, valves, and fittings shall be insulated with factory pre-molded, prefabricated, or field-fabricated sections of insulation of the same material and thickness as the adjoining pipe insulation. Insulation sections shall be secured as recommended by the manufacturer. g. Insulation, including fittings, shall be finished with three coats of asphaltic mastic, with 6 by 5.5 mesh synthetic reinforcing fabric embedded between coats. Fabric shall be overlapped a minimum of 2 inches at joints. Total film thickness shall be a minimum of 3/16 inch. As an alternate, a prefabricated bituminous laminated jacket, reinforced with internal reinforcement mesh, shall be applied to the insulation. Jacketing material and application procedures shall match manufacturer's written instructions. Vapor barrier - less than 0.0000 permeability self adhesive (minimum 2 mils adhesive, 3 mils embossed) jacket greater than 3 ply, standard grade, silver, white, black and embossed or greater than 8 ply (minimum 2.9 mils adhesive), heavy duty, white or natural). Application procedures shall match the manufacturer's written instructions. h. At termination points, other than building entrances, the mastic and cloth or tape shall cover the ends of insulation and extend 2 inches along the bare pipe. 3.3 DUCT INSULATION SYSTEMS INSTALLATION
Except for oven hood exhaust duct insulation, cCorner angles shall be installed on external corners of insulation on ductwork in exposed finished spaces before covering with jacket. [Duct insulation shall be omitted on exposed supply and return ducts in air conditioned spaces [where the difference between supply air temperature and room air temperature is less than 15 degrees F] unless otherwise shown.] Air conditioned spaces shall be defined as those spaces directly supplied with cooled conditioned air SECTION 23 07 00 Page 27
123044
(or provided with a cooling device such as a fan-coil unit) and heated conditioned air (or provided with a heating device such as a unit heater, radiator or convector). 3.3.1 Duct Insulation Thickness
Duct insulation thickness shall be in accordance with Table 4. Table 4 - Minimum Duct Insulation (inches)
Cold Air Ducts, located indoors Cold Air Ducts, located outdoors Return Air Ducts, located indoors Return Air Ducts, located outdoors 2.0 Relief Ducts Fresh Air Intake Ducts Warm Air Ducts Relief Ducts Fresh Air Intake Ducts
2.0 4.0 2.0 4.0 1.5 1.5 2.0 1.5 1.5
Cover ductwork located outdoors with aluminum jacketing 3.3.2 Insulation and Vapor Retarder/Vapor Barrier for Cold Air Duct
Insulation and vapor retarder/vapor barrier shall be provided for the following cold air ducts and associated equipment. a. b. c. d. e. f. gf. h. i. j. k. l. m. n. Supply ducts. Return air ducts. Relief ducts. Flexible run-outs (field-insulated). Plenums. Duct-mounted coil casings. Coil headers and return bends. Coil casings. Fresh air intake ducts. Filter boxes. Mixing boxes (field-insulated). Supply fans (field-insulated). Site-erected air conditioner casings. Ducts exposed to weather.
SECTION 23 07 00
Page 28
123044
o.
Combustion air intake ducts.
Insulation for rectangular ducts shall be flexible type where concealed, minimum density 3/4 pcf, and rigid type where exposed, minimum density 3 pcf. Insulation for both concealed or exposed round/oval ducts shall be flexible type, minimum density 3/4 pcf or a semi rigid board, minimum density 3 pcf, formed or fabricated to a tight fit, edges beveled and joints tightly butted and staggered. Insulation for all exposed ducts shall be provided with either a white, paint-able, factory-applied Type I jacket or a field applied vapor retarder/vapor barrier jacket coating finish as specified, the total field applied dry film thickness shall be approximately 1/16 inch. Insulation on all concealed duct shall be provided with a factory-applied Type I or II vapor retarder/vapor barrier jacket. Duct insulation shall be continuous through sleeves and prepared openings except firewall penetrations. Duct insulation terminating at fire dampers, shall be continuous over the damper collar and retaining angle of fire dampers, which are exposed to unconditioned air and which may be prone to condensate formation. Duct insulation and vapor retarder/vapor barrier shall cover the collar, neck, and any un-insulated surfaces of diffusers, registers and grills. Vapor retarder/vapor barrier materials shall be applied to form a complete unbroken vapor seal over the insulation. Sheet Metal Duct shall be sealed in accordance with Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEM. 3.3.2.1 Installation on Concealed Duct
a. For rectangular, oval or round ducts, flexible insulation shall be attached by applying adhesive around the entire perimeter of the duct in 6 inch wide strips on 12 inch centers. b. For rectangular and oval ducts, 24 inches and larger insulation shall be additionally secured to bottom of ducts by the use of mechanical fasteners. Fasteners shall be spaced on 16 inch centers and not more than 16 inches from duct corners. c. For rectangular, oval and round ducts, mechanical fasteners shall be provided on sides of duct risers for all duct sizes. Fasteners shall be spaced on 16 inch centers and not more than 16 inches from duct corners. d. Insulation shall be impaled on the mechanical fasteners (self stick pins) where used and shall be pressed thoroughly into the adhesive. Care shall be taken to ensure vapor retarder/vapor barrier jacket joints overlap 2 inches. The insulation shall not be compressed to a thickness less than that specified. Insulation shall be carried over standing seams and trapeze-type duct hangers. e. Where mechanical fasteners are used, self-locking washers shall be installed and the pin trimmed and bent over. f. Jacket overlaps shall be secured with staples and tape as necessary to ensure a secure seal. Staples, tape and seams shall be coated with a brush coat of vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate (minimum 2 mils adhesive, 3 mils embossed) - less than 0.0000 perm adhesive tape. g. Breaks in the jacket material shall be covered with patches of the same material as the vapor retarder jacket. The patches shall extend not less than 2 inches beyond the break or penetration in all SECTION 23 07 00 Page 29
123044
directions and shall be secured with tape and staples. Staples and tape joints shall be sealed with a brush coat of vapor retarder coating or PVDC adhesive tape or greater than 3 ply laminate (minimum 2 mils adhesive, 3 mils embossed) - less than 0.0000 perm adhesive tape. h. At jacket penetrations such as hangers, thermometers, and damper operating rods, voids in the insulation shall be filled and the penetration sealed with a brush coat of vapor retarder coating or PVDC adhesive tape greater than 3 ply laminate (minimum 2 mils adhesive, 3 mils embossed) - less than 0.0000 perm adhesive tape. i. Insulation terminations and pin punctures shall be sealed and flashed with a reinforced vapor retarder coating finish or tape with a brush coat of vapor retarder coating.. The coating shall overlap the adjoining insulation and un-insulated surface 2 inches. Pin puncture coatings shall extend 2 inches from the puncture in all directions. j. Where insulation standoff brackets occur, insulation shall be extended under the bracket and the jacket terminated at the bracket. 3.3.2.2 Installation on Exposed Duct Work
a. For rectangular ducts, rigid insulation shall be secured to the duct by mechanical fasteners on all four sides of the duct, spaced not more than 12 inches apart and not more than 3 inches from the edges of the insulation joints. A minimum of two rows of fasteners shall be provided for each side of duct 12 inches and larger. One row shall be provided for each side of duct less than 12 inches. Mechanical fasteners shall be as corrosion resistant as G60 coated galvanized steel, and shall indefinitely sustain a 50 lb tensile dead load test perpendicular to the duct wall. b. Duct insulation shall be formed with minimum jacket seams. Each piece of rigid insulation shall be fastened to the duct using mechanical fasteners. When the height of projections is less than the insulation thickness, insulation shall be brought up to standing seams, reinforcing, and other vertical projections and shall not be carried over. Vapor retarder/barrier jacket shall be continuous across seams, reinforcing, and projections. When height of projections is greater than the insulation thickness, insulation and jacket shall be carried over. Apply insulation with joints tightly butted. Neatly bevel insulation around name plates and access plates and doors. c. Insulation shall be impaled on the fasteners; self-locking washers shall be installed and the pin trimmed and bent over. d. Joints in the insulation jacket shall be sealed with a 4 inch wide strip of tape. Tape seams shall be sealed with a brush coat of vapor retarder coating. e. Breaks and ribs or standing seam penetrations in the jacket material shall be covered with a patch of the same material as the jacket. Patches shall extend not less than 2 inches beyond the break or penetration and shall be secured with tape and stapled. Staples and joints shall be sealed with a brush coat of vapor retarder coating. f. At jacket penetrations such as hangers, thermometers, and damper operating rods, the voids in the insulation shall be filled and the penetrations sealed with a brush coat of vapor retarder coating. SECTION 23 07 00 Page 30
123044
g. Insulation terminations and pin punctures shall be sealed and flashed with a reinforced vapor retarder coating finish. The coating shall overlap the adjoining insulation and un-insulated surface 2 inches. Pin puncture coatings shall extend 2 inches from the puncture in all directions. h. Oval and round ducts, flexible type, shall be insulated with factory Type I jacket insulation with minimum density of 3/4 pcf, attached as in accordance with MICA standards. 3.3.3 Insulation for Warm Air Duct
Insulation and vapor barrier shall be provided for the following warm air ducts and associated equipment:. a. b. c. d. e. f. gf. h. i. j. k. l. m. n. Supply ducts. Return air ducts. Relief air ducts Flexible run-outs (field insulated). Plenums. Duct-mounted coil casings. Coil-headers and return bends. Coil casings. Fresh air intake ducts. Filter boxes. Mixing boxes. Supply fans. Site-erected air conditioner casings. Ducts exposed to weather.
Insulation for rectangular ducts shall be flexible type where concealed, and rigid type where exposed. Insulation on exposed ducts shall be provided with a white, paint-able, factory-applied Type II jacket, or finished with adhesive finish. Flexible type insulation shall be used for round ducts, with a factory-applied Type II jacket. Insulation on concealed duct shall be provided with a factory-applied Type II jacket. Adhesive finish where indicated to be used shall be accomplished by applying two coats of adhesive with a layer of glass cloth embedded between the coats. The total dry film thickness shall be approximately 1/16 inch. Duct insulation shall be continuous through sleeves and prepared openings. Duct insulation shall terminate at fire dampers and flexible connections. 3.3.3.1 a. Installation on Concealed Duct For rectangular, oval and round ducts, insulation shall be attached SECTION 23 07 00 Page 31
123044
by applying adhesive around the entire perimeter of the duct in 6 inch wide strips on 12 inch centers. b. For rectangular and oval ducts 24 inches and larger, insulation shall be secured to the bottom of ducts by the use of mechanical fasteners. Fasteners shall be spaced on 18 inch centers and not more than 18 inches from duct corner. c. For rectangular, oval and round ducts, mechanical fasteners shall be provided on sides of duct risers for all duct sizes. Fasteners shall be spaced on 18 inch centers and not more than 18 inches from duct corners. d. The insulation shall be impaled on the mechanical fasteners where used. The insulation shall not be compressed to a thickness less than that specified. Insulation shall be carried over standing seams and trapeze-type hangers. e. Self-locking washers shall be installed where mechanical fasteners are used and the pin trimmed and bent over. f. Insulation jacket shall overlap not less than 2 inches at joints and the lap shall be secured and stapled on 4 inch centers. 3.3.3.2 Installation on Exposed Duct
a. For rectangular ducts, the rigid insulation shall be secured to the duct by the use of mechanical fasteners on all four sides of the duct, spaced not more than 16 inches apart and not more than 6 inches from the edges of the insulation joints. A minimum of two rows of fasteners shall be provided for each side of duct 12 inches and larger and a minimum of one row for each side of duct less than 12 inches. b. Duct insulation with factory-applied jacket shall be formed with minimum jacket seams, and each piece of rigid insulation shall be fastened to the duct using mechanical fasteners. When the height of projection is less than the insulation thickness, insulation shall be brought up to standing seams, reinforcing, and other vertical projections and shall not be carried over the projection. Jacket shall be continuous across seams, reinforcing, and projections. Where the height of projections is greater than the insulation thickness, insulation and jacket shall be carried over the projection. c. Insulation shall be impaled on the fasteners; self-locking washers shall be installed and pin trimmed and bent over. d. Joints on jacketed insulation shall be sealed with a 4 inch wide strip of tape and brushed with vapor retarder coating. e. Breaks and penetrations in the jacket material shall be covered with a patch of the same material as the jacket. Patches shall extend not less than 2 inches beyond the break or penetration and shall be secured with adhesive and stapled. f. Insulation terminations and pin punctures shall be sealed with tape and brushed with vapor retarder coating. g. Oval and round ducts, flexible type, shall be insulated with factory Type I jacket insulation, minimum density of 3/4 pcf attached SECTION 23 07 00 Page 32
123044
by staples spaced not more than 16 inches and not more than 6 inches from the degrees of joints. Joints shall be sealed in accordance with item "d." above. 3.3.4 Ducts Handling Air for Dual Purpose
For air handling ducts for dual purpose below and above 60 degrees F, ducts shall be insulated as specified for cold air duct. 3.3.5 Insulation for Evaporative Cooling Duct
Evaporative cooling supply duct located in spaces not evaporatively cooled, shall be insulated. Material and installation requirements shall be as specified for duct insulation for warm air duct. 3.3.5 Duct Test Holes
After duct systems have been tested, adjusted, and balanced, breaks in the insulation and jacket shall be repaired in accordance with the applicable section of this specification for the type of duct insulation to be repaired. 3.3.7 3.3.7.1 Duct Exposed to Weather Installation
Ducts exposed to weather shall be insulated and finished as specified for the applicable service for exposed duct inside the building. After the above is accomplished, the insulation shall then be further finished as detailed in the following subparagraphs. 3.3.7.2 Round Duct
Laminated self-adhesive (minimum 2 mils adhesive, 3 mils embossed) vapor barrier/weatherproofing jacket - Less than 0.0000 permeability, (greater than 3 ply, standard grade, silver, white, black and embossed or greater than 8 ply, heavy duty, white and natural) membrane shall be applied overlapping material by 3 inches no bands or caulking needed - see manufacturer's recommended installation instructions. Aluminum jacket with factory applied moisture retarder shall be applied with the joints lapped not less than 3 inches and secured with bands located at circumferential laps and at not more than 12 inch intervals throughout. Horizontal joints shall lap down to shed water and located at 4 or 8 o'clock position. Joints shall be sealed with caulking to prevent moisture penetration. Where jacketing abuts an un-insulated surface, joints shall be sealed with caulking. 3.3.7.3 Fittings
Fittings and other irregular shapes shall be finished as specified for rectangular ducts. 3.3.7.4 Rectangular Ducts
Two coats of weather barrier mastic reinforced with fabric or mesh for outdoor application shall be applied to the entire surface. Each coat of weatherproof mastic shall be 1/16 inch minimum thickness. The exterior shall be a metal jacketing applied for mechanical abuse and weather protection, and secured with screws. SECTION 23 07 00 Page 33
123044
3.3.8
Kitchen Exhaust Duct Insulation
NFPA 96 for [ovens,] [griddles,] [deepfat fryers,] [steam kettles,] [vegetable steamers,] [high pressure cookers,] [and] [mobile serving units]. Provide insulation with 3/4 inch wide, minimum 0.15 inch thick galvanized steel bands spaced not over 12 inches o.c.; or 16 gauge galvanized steel wire with corner clips under the wire; or with heavy welded pins spaced not over 12 inches apart each way. Do not use adhesives. 3.4 3.4.1 EQUIPMENT INSULATION SYSTEMS INSTALLATION General
Removable insulation sections shall be provided to cover parts of equipment that must be opened periodically for maintenance including vessel covers, fasteners, flanges and accessories. Equipment insulation shall be omitted on the following: a. b. c. d. e. f. 3.4.2 Hand-holes. Boiler manholes. Cleanouts. ASME stamps. Manufacturer's nameplates. Duct Test/Balance Test Holes.
Insulation for Cold Equipment
Cold equipment below 60 degrees F: Insulation shall be furnished on equipment handling media below 60 degrees F including the following: a. b. cb. d. e. f. gc. h. i. jd. ke. Pumps. Refrigeration equipment parts that are not factory insulated. Drip pans under chilled equipment. Cold water storage tanks. Water softeners. Duct mounted coils. Cold and chilled water pumps. Pneumatic water tanks. Roof drain bodies. Air handling equipment parts that are not factory insulated. Expansion and air separation tanks, and Thermal Storage Buffer Tank.
SECTION 23 07 00
Page 34
123044
3.4.2.1
Insulation Type Material and
Insulation shall be suitable for the temperature encountered. thicknesses shall be as shown in Table 5: Legend RMF: FMF: CS: PL: CG: FC: PF: PC: PE: Rigid Mineral Fiber Flexible Mineral Fiber Calcium Silicate Perlite Cellular Glass Flexible Elastomeric Cellular Phenolic Foam Polyisocyanurate Foam Polyolefin closed cell
TABLE 5 Insulation Thickness for Cold Equipment (Inches and F) Equipment handling media Material Thickness at indicated temperature: _________________________________________________________________________ 35 to 60 degrees F CG PFFC FC PC PE 1.5 inches 1.50 inches 1.0 inches 1.0 inches 1.0 inches
__ 1 to 34 degrees F
PC 1.5 inches FC 1.5 inches CG 3.0 inches PF 1.5 inches PE 1.5 inches _________________________________________________________________________ Minus 30 to 0 PC 1.5 inches degrees F FC 1.75 inches CG 3.5 inches PF 1.5 inches PE 1.5 inches _________________________________________________________________________ 3.4.2.2 Pump Insulation
a. Insulate pumps by forming a box around the pump housing. The box shall be constructed by forming the bottom and sides using joints that do not leave raw ends of insulation exposed. Joints between sides and between sides and bottom shall be joined by adhesive with lap strips for rigid mineral fiber and contact adhesive for flexible elastomeric cellular insulation. The box shall conform to the requirements of MICA Insulation Stds plate No. 49 when using flexible elastomeric cellular insulation. Joints between top cover and sides shall fit tightly forming a female shiplap joint on the side pieces and a male joint on the top cover, thus making the top cover removable. b. c. Exposed insulation corners shall be protected with corner angles. Upon completion of installation of the insulation, including SECTION 23 07 00 Page 35
123044
removable sections, two coats of vapor retarder coating shall be applied with a layer of glass cloth embedded between the coats. The total dry thickness of the finish shall be 1/16 inch. A parting line shall be provided between the box and the removable sections allowing the removable sections to be removed without disturbing the insulation coating. Caulking shall be applied to parting line, between equipment and removable section insulation, and at all penetrations. 3.4.2.3 Other Equipment To
a. Insulation shall be formed or fabricated to fit the equipment. ensure a tight fit on round equipment, edges shall be beveled and joints shall be tightly butted and staggered.
b. Insulation shall be secured in place with bands or wires at intervals as recommended by the manufacturer but not more than 12 inch centers except flexible elastomeric cellular which shall be adhered with contact adhesive. Insulation corners shall be protected under wires and bands with suitable corner angles. c. Phenolic foam insulation shall be set in a coating of bedding compound and joints shall be sealed with bedding compound as recommended by the manufacturer. Cellular glass shall be installed in accordance with manufacturer's instructions. Joints and ends shall be sealed with joint sealant, and sealed with a vapor retarder coating. d. Insulation on heads of heat exchangers shall be removable. Removable section joints shall be fabricated using a male-female shiplap type joint. The entire surface of the removable section shall be finished by applying two coats of vapor retarder coating with a layer of glass cloth embedded between the coats. The total dry thickness of the finish shall be 1/16 inch. e. Exposed insulation corners shall be protected with corner angles.
f. Insulation on equipment with ribs shall be applied over 6 by 6 inches by 12 gauge welded wire fabric which has been cinched in place, or if approved by the Contracting Officer, spot welded to the equipment over the ribs. Insulation shall be secured to the fabric with J-hooks and 2 by 2 inches washers or shall be securely banded or wired in place on 12 inch centers. 3.4.2.4 Vapor Retarder/Vapor Barrier
Upon completion of installation of insulation, penetrations shall be caulked. Two coats of vapor retarder coating or vapor barrier jacket shall be applied over insulation, including removable sections, with a layer of open mesh synthetic fabric embedded between the coats. The total dry thickness of the finish shall be 1/16 inch. Caulking or vapor barrier tape shall be applied to parting line between equipment and removable section insulation. 3.4.3 Insulation for Hot Equipment
Insulation shall be furnished on equipment handling media above 60 degrees F including the following: a. Converters.
SECTION 23 07 00
Page 36
123044
b. c. d. ea. f. gb. hc. i. j. k. l. m. n. o. p. 3.4.3.1
Heat exchangers. Hot water generators. Water heaters. Pumps handling media above 130 degrees F. Fuel oil heaters. Hot water storage tanks. Air separation tanks. Surge tanks. Flash tanks. Feed-water heaters. Unjacketed boilers or parts of boilers. Boiler flue gas connection from boiler to stack (if inside). Induced draft fans. Fly ash and soot collectors. Condensate receivers. Insulation
Insulation shall be suitable for the temperature encountered. Shell and tube-type heat exchangers shall be insulated for the temperature of the shell medium. Insulation thickness for hot equipment shall be determined using Table 6: Legend RMF: FMF: CS: PL: CG: FC: PF: PC: Rigid Mineral Fiber Flexible Mineral Fiber Calcium Silicate Perlite Cellular Glass Flexible Elastomeric Cellular Phenolic Foam Polyisocyanurate Foam
SECTION 23 07 00
Page 37
123044
TABLE 6 Insulation Thickness for Hot Equipment (Inches and F) Equipment handling steam Material Thickness or media to indicated pressure or temperature limit: _________________________________________________________________________ 15 psig or 250 F RMF FMF CS/PL CG PF FC (<200F) PC 2.0 inches 2.0 inches 4.0 inches 3.0 inches 1.5 inches 1.0 inches 1.0 inches
__ 200 psig or 400 F
RMF 3.0 inches FMF 3.0 inches CS/PL 4.0 inches CG 4.0 inches _________________________________________________________________________ 600 F RMF 5.0 inches FMF 6.0 inches CS/PL 6.0 inches CG 6.0 inches _________________________________________________________________________ >600 F: Thickness necessary to limit the external temperature of the insulation to 120F. Heat transfer calculations shall be submitted to substantiate insulation and thickness selection. 3.4.3.2 Insulation of Boiler Stack and Diesel Engine Exhaust Pipe
Inside [boiler House] [mechanical Room], bevel insulation neatly around openings and provide sheet metal insulation stop strips around such openings. Apply a skim coat of hydraulic setting cement directly to insulation. Apply a flooding coat of adhesive over hydraulic setting cement, and while still wet, press a layer of glass cloth or tape into adhesive and seal laps and edges with adhesive. Coat glass cloth with adhesive. When dry, apply a finish coat of adhesive at can-consistency so that when dry no glass weave shall be observed. Provide metal jackets for [stacks] [and] [exhaust pipes] that are located above finished floor and spaces outside [boiler house] [mechanical room]. Apply metal jackets directly over insulation and secure with 3/4 inch wide metal bands spaced on 18 inch centers. Do not insulate name plates. Insulation type and thickness shall be in accordance with the following Table 7. TABLE 7 Insulation and Thickness (Inches and F) for Boiler Stack and Diesel Engine Exhaust Pipe ___________________________________________________________________________ Service & Surface Material Outside Diameter (Inches) Temperature Range 1/4-1-1/4 1-1/2-3 3-1/2-5 6-10 11-36 (Degrees F) ___________________________________________________________________________ Boiler Stack (Up to 400 F) Mineral Fiber ASTM C 553 Class B-3, NA NA 3 3.5 4
SECTION 23 07 00
Page 38
123044
TABLE 7 Insulation and Thickness (Inches and F) for Boiler Stack and Diesel Engine Exhaust Pipe ___________________________________________________________________________ Service & Surface Material Outside Diameter (Inches) Temperature Range 1/4-1-1/4 1-1/2-3 3-1/2-5 6-10 11-36 (Degrees F) ___________________________________________________________________________ ASTM C 547 Class 1, or ASTM C 612 Class 1 ________________________________________________________ Calcium Silicate NA NA 3 3.5 4 ASTM C 533, Type 1 ________________________________________________________ Cellular Glass 1.5 1.5 1.5 2 2.5 ASTM C 552, Type II ___________________________________________________________________________ Boiler Stack Mineral Fiber NA NA 4 4 5 (401 to 600F) ASTM C 547, Class 2, ASTM C 592 Class 1, or ASTM C 612 Class 3 ________________________________________________________ Calcium Silicate NA NA 4 4 4 ASTM C 533 Type I or II ________________________________________________________ Mineral Fiber/ Cellular Glass Composite: Mineral Fiber 1 ASTM C 547 Class 2 ASTM C 592 Class 1, or ASTM C 612 Class 3 1 1 1 2
Cellular Glass 2 2 2 2 2 ASTM C 552, Type II ___________________________________________________________________________ Boiler Stack Mineral Fiber NA NA 4 4 6 (601 to 800F) ASTM C 547 Class 3, ASTM C 592 Class 1, or ASTM C 612 Class 3 ________________________________________________________ Calcium Silicate NA NA 4 4 6 SECTION 23 07 00 Page 39
123044
TABLE 7 Insulation and Thickness (Inches and F) for Boiler Stack and Diesel Engine Exhaust Pipe ___________________________________________________________________________ Service & Surface Material Outside Diameter (Inches) Temperature Range 1/4-1-1/4 1-1/2-3 3-1/2-5 6-10 11-36 (Degrees F) ___________________________________________________________________________ ASTM C 533 Type I or II ________________________________________________________ Mineral Fiber/ Cellular Glass Composite: Mineral Fiber 2 ASTM C 547, Class 2, ASTM C 592 Class 1, or ASTM C 612 Class 3 2 2 3 4
Cellular Glass 2 2 2 2 2 ASTM C 552, Type II ___________________________________________________________________________ Diesel Engine Calcium Silicate 3 3.5 4 4 4 Exhaust ASTM C 533 (Up to 700F) Type I or II ________________________________________________________ Cellular Glass 2.5 3.5 4 4.5 6 ASTM C 552, Type II ___________________________________________________________________________ 3.4.3.2 Insulation of Pumps
Insulate pumps by forming a box around the pump housing. The box shall be constructed by forming the bottom and sides using joints that do not leave raw ends of insulation exposed. Bottom and sides shall be banded to form a rigid housing that does not rest on the pump. Joints between top cover and sides shall fit tightly. The top cover shall have a joint forming a female shiplap joint on the side pieces and a male joint on the top cover, making the top cover removable. Two coats of Class I adhesive shall be applied over insulation, including removable sections, with a layer of glass cloth embedded between the coats. A parting line shall be provided between the box and the removable sections allowing the removable sections to be removed without disturbing the insulation coating. The total dry thickness of the finish shall be 1/16 inch. Caulking shall be applied to parting line of the removable sections and penetrations. 3.4.3.3 Other Equipment To
a. Insulation shall be formed or fabricated to fit the equipment. ensure a tight fit on round equipment, edges shall be beveled and joints shall be tightly butted and staggered.
SECTION 23 07 00
Page 40
123044
b. Insulation shall be secured in place with bands or wires at intervals as recommended by the manufacturer but not greater than 12 inch centers except flexible elastomeric cellular which shall be adhered. Insulation corners shall be protected under wires and bands with suitable corner angles. c. On high vibration equipment, cellular glass insulation shall be set in a coating of bedding compound as recommended by the manufacturer, and joints shall be sealed with bedding compound. Mineral fiber joints shall be filled with finishing cement. d. Insulation on heads of heat exchangers shall be removable. The removable section joint shall be fabricated using a male-female shiplap type joint. Entire surface of the removable section shall be finished as specified. e. Exposed insulation corners shall be protected with corner angles.
f. On equipment with ribs, such as boiler flue gas connection, draft fans, and fly ash or soot collectors, insulation shall be applied over 6 by 6 inch by 12 gauge welded wire fabric which has been cinched in place, or if approved by the Contracting Officer, spot welded to the equipment over the ribs. Insulation shall be secured to the fabric with J-hooks and 2 by 2 inch washers or shall be securely banded or wired in place on 12 inch (maximum) centers. g. On equipment handling media above 600 degrees F, insulation shall be applied in two or more layers with joints staggered. hf. Upon completion of installation of insulation, penetrations shall be caulked. Two coats of adhesive shall be applied over insulation, including removable sections, with a layer of glass cloth embedded between the coats. The total dry thickness of the finish shall be 1/16 inch. Caulking shall be applied to parting line between equipment and removable section insulation. 3.4.4 Equipment Handling Dual Temperature Media
Below and above 60 degrees F: equipment handling dual temperature media shall be insulated as specified for cold equipment. 3.4.4 3.4.4.1 Equipment Exposed to Weather Installation
All equipment exposed to weather shall be furnished from the equipment manufacturer with all required insulation and appurtenances as required for outdoor installation. Equipment exposed to weather that is not available pre-insulated from the manufacturer shall be insulated and finished in accordance with the requirements for ducts exposed to weather in paragraph DUCT INSULATION INSTALLATION. 3.4.4.2 Optional Panels
At the option of the Contractor, prefabricated metal insulation panels may be used in lieu of the insulation and finish previously specified. Thermal performance shall be equal to or better than that specified for field applied insulation. Panels shall be the standard catalog product of a manufacturer of metal insulation panels. Fastenings, flashing, and support SECTION 23 07 00 Page 41
123044
system shall conform to published recommendations of the manufacturer for weatherproof installation and shall prevent moisture from entering the insulation. Panels shall be designed to accommodate thermal expansion and to support a 250 pound walking load without permanent deformation or permanent damage to the insulation. Exterior metal cover sheet shall be aluminum and exposed fastenings shall be stainless steel or aluminum. -- End of Section --
SECTION 23 07 00
Page 42
123044
SECTION 23 08 00.00 10 COMMISSIONING OF HVAC SYSTEMS 01/08 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. ASSOCIATED AIR BALANCE COUNCIL (AABC) ACG Commissioning Guideline (2005) Commissioning Guideline
NATIONAL ENVIRONMENTAL BALANCING BUREAU (NEBB) NEBB Commissioning Standard (2009) Procedural Standards for Whole Building Systems Commissioning of New Construction; 3rd Edition
SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA) SMACNA 1429 (1994) HVAC Systems Commissioning Manual, 1st Edition
U.S. GREEN BUILDING COUNCIL (USGBC) LEED (2002; R 2005) Leadership in Energy and Environmental Design(tm) Green Building Rating System for New Construction (LEED-NC) DEFINITIONS
1.2
In some instances, terminology differs between the Contract and the Commissioning Standard primarily because the intent of this Section is to use the industry standards specified, along with additional requirements listed herein to produce optimal results. The following table of similar terms is provided for clarification only. Contract requirements take precedent over the corresponding ACG, NEBB, or TABB requirements where differences exist.
SIMILAR TERMS Contract Term Commissioning Standard ACG NEBB TABB SMACNA HVAC Commissioning Guidelines
ACG Commissioning Procedural Guideline Standards for Building Systems Commissioning
SECTION 23 08 00.00 10
Page 1
123044
SIMILAR TERMS Contract Term Commissioning Specialist ACG ACG Certified Commissioning Agent NEBB NEBB Qualified Commissioning Administrator TABB TABB Certified Commissioning Supervisor
1.3 1.3.1
SYSTEM DESCRIPTION General
Perform Commissioning in accordance with the requirements of the standard under which the Commissioning Firm's qualifications are approved, i.e., ACG Commissioning Guideline, NEBB Commissioning Standard, or SMACNA 1429 unless otherwise stated herein. Consider mandatory all recommendations and suggested practices contained in the Commissioning Standard. Use the Commissioning Standard for all aspects of Commissioning, including qualifications for the Commissioning Firm and Specialist and calibration of Commissioning instruments. Where the instrument manufacturer calibration recommendations are more stringent than those listed in the Commissioning Standard, the manufacturer's recommendations shall be adhered to. All quality assurance provisions of the Commissioning Standard such as performance guarantees shall be part of this contract. For systems or system components not covered in the Commissioning Standard, Commissioning procedures shall be developed by the Commissioning Specialist. Where new procedures, requirements, etc., applicable to the Contract requirements have been published or adopted by the body responsible for the Commissioning Standard used (ACG, NEBB, or TABB), the requirements and recommendations contained in these procedures and requirements shall be considered mandatory. 1.3.2 Energy
Formal LEED certification is not required; however, the Contractor is required to provide documentation that meets the LEED Energy & Atmosphere (EA) Prerequisite 1, Fundamental Commissioning. For New Construction and Major Revisions provide, also, documentation that meets EA Credit 3; Enhanced Commissioning. Provide documentation for as many LEED credits as possible to support LEED Silver certification of the project. 1.4 SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for [Contractor Quality Control approval.][information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] Submit the following in accordance with Section 01 33 00.05 20 CONSTRUCTION SUBMITTAL PROCEDURES: SD-02 Shop Drawings Commissioning Plan[; G,][;G, [_____]] SD-03 Product Data Pre-Functional Performance Test Checklists[; G,][;G, [_____]] SECTION 23 08 00.00 10 Page 2
123044
Functional Performance Tests[; G,][;G, [_____]] SD-06 Test Reports Commissioning Report[; G][; G, [_____]] SD-07 Certificates Commissioning Firm[; G][; G, [_____]] Commissioning Specialist[; G][; G, [_____]] 1.5 1.5.1 QUALITY ASSURANCE Commissioning Firm
Submit certification of the proposed Commissioning Firm's qualifications to perform the duties specified herein and in other related Sections, no later than 21 days after the Notice to Proceed. Include in the documentation the date that the Certification was initially granted and the date when the current Certification expires. The firm is either a member of ACG or certified by the NEBB or the TABB and certified in all categories and functions where measurements or performance are specified on the plans and specifications. Any lapses in Certification of the proposed Commissioning Firm or disciplinary action taken by ACG, NEBB, or TABB against the proposed Commissioning Firm shall be described in detail. The certification shall be maintained for the entire duration of duties specified herein. If, for any reason, the firm loses subject certification during this period, immediately notify the Contracting Officer and submit another Commissioning Firm for approval. Any firm that has been the subject of disciplinary action by the ACG, the NEBB, or the TABB within the five years preceding Contract Award is not eligible to perform any duties related to the HVAC systems, including Commissioning. All work specified in this Section and in other related Sections to be performed by the Commissioning Firm shall be considered invalid if the Commissioning Firm loses its certification prior to Contract completion and must be performed by an approved successor. These Commissioning services are to assist the prime Contractor in performing the quality oversight for which it is responsible. The Commissioning Firm shall be a subcontractor of the prime Contractor and shall be financially and corporately independent of all other subContractorssubcontractors. The Commissioning Firm shall report to and be paid by the prime Contractor. 1.5.2 1.5.2.1 Commissioning Specialist General
Submit certification of the proposed Commissioning Specialist's qualifications to perform the duties specified herein and in other related Sections, no later than 21 days after the Notice to Proceed. The documentation shall include the date that the Certification was initially granted and the date when the current Certification expires. The Commissioning Specialist shall be an ACG Certified Commissioning Agent, a NEBB Qualified Commissioning Administrator, or a TABB Certified Commissioning Supervisor and shall be an employee of the approved Commissioning Firm. Any lapses in Certification of the proposed Commissioning Specialist or disciplinary action taken by ACG, NEBB, or TABB against the proposed Commissioning Specialist shall be described in detail. The certification shall be maintained for the entire duration of duties specified herein. If, for any reason, the Commissioning Specialist SECTION 23 08 00.00 10 Page 3
123044
loses subject certification during this period, immediately notify the Contracting Officer and submit another Commissioning Specialist for approval. Any individual that has been the subject of disciplinary action by the ACG, the NEBB, or the TABB within the five years preceding Contract Award is not eligible to perform any duties related to the HVAC systems, including Commissioning. All work specified in this Section and in other related Sections performed by the Commissioning Specialist shall be considered invalid if the Commissioning Specialist loses certification prior to Contract completion and must be performed by the approved successor. 1.5.2.2 Responsibilities
Perform all Commissioning work specified herein and in related sections under the direct guidance of the Commissioning Specialist. The Commissioning Specialist shall prepare, no later than 28 days after the approval of the Commissioning Specialist, the Commissioning Plan which will be a comprehensive schedule and will include all submittal requirements for procedures, notifications, reports and the Commissioning Report. After approval of the Commissioning Plan, revise the Contract NAS schedule to reflect the schedule requirements in the Commissioning Plan. 1.6 SEQUENCING AND SCHEDULING
Begin the work described in this Section only after all work required in related Sections has been successfully completed, and all test and inspection reports and operation and maintenance manuals required in these Sections have been submitted and approved. Pre-Functional Performance Test Checklists shall be performed at appropriate times during the construction phase of the Contract. PART 2 PRODUCTS
Not Used PART 3 3.1 EXECUTION COMMISSIONING TEAM AND TEST FORMS AND CHECKLISTS
Designate Contractor team members to participate in the Pre- Functional Performance Test Checklists and the Functional Performance Tests specified herein. In addition, the Government team members will include a representative of the Contracting Officer, the Design Agent's Representative, and the Using Agency's Representative. The team members shall be as follows:
Designation A M E T
Function Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's Testing, Adjusting, and Balancing (TAB) Specialist
SECTION 23 08 00.00 10
Page 4
123044
Designation C D O U
Function Contractor's Controls Representative Design Agency Representative Contracting Officer's Representative Using Agency's Representative
Appendices A and B shall be completed by the commissioning team. Acceptance by each commissioning team member of each Pre- Functional Performance Test Checklist item shall be indicated by initials and date unless an "X" is shown indicating that participation by that individual is not required. Acceptance by each commissioning team member of each functional performance test item shall be indicated by signature and date. 3.2 TESTS
Perform the pre-functional performance test checklists and functional performance tests in a manner that essentially duplicates the checking, testing, and inspection methods established in the related Sections. Where checking, testing, and inspection methods are not specified in other Sections, establish methods which will provide the information required. Testing and verification required by this section shall be performed during the Commissioning phase. Requirements in related Sections are independent from the requirements of this Section and shall not be used to satisfy any of the requirements specified in this Section. Provide all materials, services, and labor required to perform the pre- functional performance tests checks and functional performance tests. A functional performance test shall be aborted if any system deficiency prevents the successful completion of the test or if any participating non-Government commissioning team member of which participation is specified is not present for the test. 3.2.1 Pre-Functional Performance Test Checklists
Perform Pre-Functional Performance Test Checklists, for the items indicated in Appendix A, at least 28 days prior to the start of Pre-Functional Performance Test Checks.. Correct and re-inspect deficiencies discovered during these checks in accordance with the applicable contract requirements. Submit the schedule for the test checks at least 14 days prior to the start of Pre-Functional Performance Test Checks. 3.2.2 Functional Performance Tests
Submit test procedures at least 28 days prior to the start of Functional Performance Tests. Submit the schedule for the tests at least 14 days prior to the start of Functional Performance Tests. Perform Functional Performance Tests for the items indicated in Appendix B. Begin Functional Performance Tests only after all Pre-Functional Performance Test Checklists have been successfully completed. Tests shall prove all modes of the sequences of operation, and shall verify all other relevant contract requirements. Begin Tests with equipment or components and progress through subsystems to complete systems. Upon failure of any Functional Performance Test item, correct all deficiencies in accordance with the applicable contract requirements. The item shall then be retested until it has been completed with no errors.
SECTION 23 08 00.00 10
Page 5
123044
3.3
COMMISSIONING REPORT
Submit the Commissioning Report, no later than 14 days after completion of Functional Performance Tests, consisting of completed Pre- Functional Performance Test Checklists and completed Functional Performance Tests organized by system and by subsystem and submitted as one package. The Commissioning Report shall also include all HVAC systems test reports, inspection reports (Preparatory, Initial and Follow-up inspections), start-up reports, TAB report, TAB verification report, Controls start-up test reports and Controls Performance Verification Test (PVT) report. The results of failed tests shall be included along with a description of the corrective action taken.
SECTION 23 08 00.00 10
Page 6
123044
APPENDIX A PRE-FUNCTIONAL PERFORMANCE TEST CHECKLISTS
Refer to attached Pre-Functional Performance Test Checklists: Pre Pre Pre Pre Pre Pre Pre Pre Pre Pre Pre Pre Functional Functional Functional Functional Functional Functional Functional Functional Functional Functional Functional Functional Test Test Test Test Test Test Test Test Test Test Test Test Checklist Checklist Checklist Checklist Checklist Checklist Checklist Checklist Checklist Checklist Checklist Checklist Chiller Air Handling Units Energy Recovery System Boilers Pumps HVAC System Controls (Entire BAS) Fans Fan Coil Units Packaged DX Unit Unit Heaters VAV Terminals (10% Representation) VRF System
SECTION 23 08 00.00 10
Page 7
123044
APPENDIX B FUNCTIONAL PERFORMANCE TEST CHECKLISTS
Refer to attached Functional Performance Test Checklists: Functional Functional Functional Functional Functional Functional Functional Functional Functional Functional Functional Functional Test Test Test Test Test Test Test Test Test Test Test Test Checklist-Chiller Checklist-Air Handling Units Checklist-Energy Recovery System Checklist-Boilers Checklist-Pumps Checklist-HVAC Controls (Entire BAS) Checklist-Fans Checklist-Fan Coil Units Checklist-Unit Heaters Checklist-Packaged DX Unit Checklist-VAV Terminals (10% Representation) Checklist-VRF System
SECTION 23 08 00.00 10
Page 8
123044
Pre-Functional Performance Test Checklist - Multizone Air Handling Unit For Air Handling Unit: Checklist Item Installation a. Inspection and access doors are operable and sealed. b. Condensate drainage is unobstructed. (Visually verify pan drains completely by pouring a cup of water into drain pan.) c. Fan belt adjusted. [_____] A M E T C O
___ ___
___
___
___ ___ ___ ___
X X
X ___
X X
___ ___
Electrical a. b. c. d. Power available to unit disconnect. Power available to unit control panel. Proper motor rotation verified. Verify that power disconnect is located within sight of the unit it controls.
A ___ ___ ___
M X X X
E ___ ___
T X X
C X X X
O ___ ___ ___
___ ___
___ ___
X X
___ ___
X X
X X
___ ___ ]
[e. Power available to electric heating coil.
Coils [a. [a. [b. [b. Chilled water piping properly connected. Refrigerant piping properly connected. Hot water piping properly connected. Steam and condensate piping properly connected.
E X X X
T X X X
C X X X
O ___ ] ___ ] ___ ]
___ ___ ___ ___ ___ ___
___ ___
___ ]
Controls a. Control valves/actuators properly installed. Control valves/actuators operable. O/A dampers/actuators properly installed. O/A dampers/actuators operable.
___ ___ ___ ___
X X X X
X X X X
X X X X
___ ___ ___ ___ ___ ___ ___ ___
b. c. d.
Pre-Functional Performance Test Checklist - Multizone Air Handling Unit (cont) A SECTION 23 08 00.00 10 Page 9 M E T C O
123044
e.
Zone dampers/actuators properly installed & dampers leak checked. Zone dampers/actuators operable.
___ ___
X X
X X
X X
___ ___ ___ ___
f.
Testing, Adjusting, and Balancing (TAB) a. Construction filters removed and replaced. TAB report approved.
___ ___ ___
X X
___ X
X ___
___ X
b.
SECTION 23 08 00.00 10
Page 10
123044
Pre-Functional Performance Test Checklist - Variable Volume Air Handling Unit For Air Handling Unit: Checklist Item Installation a. Inspection and access doors are operable and sealed. b. Condensate drainage is unobstructed. (Visually verify drainage by pouring a cup of water into drain pan.) Fan belt adjusted. [_____] A M E T C O
___ ___
___
___
___ ___ ___ ___
X X
X ___
X X
___ ___
c.
Electrical a. b. c. d. Power available to unit disconnect. Power available to unit control panel. Proper motor rotation verified. Verify that power disconnect is located within sight of the unit it controls.
A ___ ___ ___
M X X X
E ___ ___
T X X
C X X X
O ___ ___ ___
___ ___
___ ___
X X
___ ___
X X
X X
___ ___]
[e. Power available to electric heating coil.
Coils [a. [a. [b. [b. Chilled water piping properly connected. Refrigerant piping properly connected. Hot water piping properly connected. Steam and condensate piping properly connected.
E X X X
T X X X
C X X X
O ___] ___] ___]
___ ___ ___ ___ ___ ___
___ ___
___]
SECTION 23 08 00.00 10
Page 11
123044
Pre-Functional Performance Test Checklist - Variable Volume Air Handling Unit Controls a. Control valves/actuators properly installed. Control valves/actuators operable. Dampers/actuators properly installed. Dampers/actuators operable. Verify proper location, installation and calibration of duct static pressure sensor. Fan air volume controller operable. Air handler controls system operational. A M E T C O
___ ___ ___ ___
X X X X
X X X X
X X X X
___ ___ ___ ___ ___ ___ ___ ___
b. c. d. e.
___ ___ ___
X X X
X X X
X X X
___ ___ ___ ___ ___ ___
f. g.
Testing, Adjusting, and Balancing (TAB) a. Construction filters removed and replaced. TAB report approved.
___ ___ ___ X
X X
___ ___ ___ ___ X ___
b.
SECTION 23 08 00.00 10
Page 12
123044
Pre-Functional Performance Test Checklist - VAV Terminal For VAV Terminal: Checklist Item Installation [a. [b. Reheat coil connected to hot water pipe. Electric reheat coil connected to local disconnect. ___ ___ X ___ X ___] [_____] A M E T C O
___
___ ___
___]
Controls a. b. c. d. Cooling only VAV terminal controls set. Cooling only VAV controls verified. Reheat VAV terminal controls set. Reheat terminal/coil controls verified.
A ___ ___ ___ ___
M X X X X
E X X X X
T X X X X
___ ___ ___ ___ ___ ___ ___ ___
Testing, Adjusting, and Balancing (TAB) a. TAB report approved.
E X
T ___
C X
O ___
___ ___
SECTION 23 08 00.00 10
Page 13
123044
Pre-Functional Performance Test Checklist - DX Air Cooled Condensing Unit For Condensing Unit: Checklist Item Installation a. Check condenser fans for proper rotation. ___ ___ X ___ X ___ [_____] A M E T C O
Electrical a. b. c. Power available to unit disconnect. Power available to unit control panel. Verify that power disconnect is located within sight of the unit it controls
A ___ ___
M X X
E ___ ___
T X X
C X
O ___
___ ___
___
___
___ ___
Controls a. b. Unit safety/protection devices tested. Control system and interlocks installed.
E X X
T X X
___ ___ ___ ___
___ ___ ___ ___
c. Control system and interlocks operational.
___ ___
___ ___
SECTION 23 08 00.00 10
Page 14
123044
Pre-Functional Performance Test Checklist - Pumps For Pump: [_____] A M E T C O
Checklist Item Installation a. Piping system installed.
___ ___
___
Electrical a. b. c. Power available to pump disconnect. Pump rotation verified. Control system interlocks functional.
A ___ ___ ___
M X X X
E ___ ___ ___
T X X X
C X X
O ___ ___
___ ___
Testing, Adjusting, and Balancing (TAB) a. b. Pressure/temperature gauges installed. TAB Report approved.
E X X
T ___ ___
C X X
O ___ ___
___ ___ ___ ___
SECTION 23 08 00.00 10
Page 15
123044
Pre-Functional Performance Test Checklist - Packaged Air Cooled Chiller For Chiller: Checklist Item Installation a. Chiller properly piped. ___ ___ X ___ ___ ___ [_____] A M E T C O
Electrical a. b. c. Power available to unit disconnect. Power available to unit control panel. Separate power is supplied to electric heating tape. Verify that power disconnect is located within sight of the unit it controls.
A ___ ___
M X X
E ___ ___
T X X
___ ___ ___ ___
___
___
___ ___
d.
___
___
___ ___
Controls a. b. c. d. e. f. Factory startup and checkout complete. Chiller safety/protection devices tested. Chilled water flow switch installed. Chilled water flow switch tested. Chilled water pump interlock installed. Chilled water pump interlock tested.
E X X X X X
T X X X X X X
___ ___ ___ ___ ___ ___ ___ ___ ___ ___
___ ___ ___ ___ ___ ___ ___ ___ X ___
___ ___ ___
SECTION 23 08 00.00 10
Page 16
123044
Pre-Functional Performance Test Checklist - Centrifugal Chiller For Chiller: Checklist Item Installation a. b. Chilled water connections properly piped. Condenser water connections properly piped Refrigerant leak detector installed. Oxygen sensor installed and tested. Mechanical room ventilation installed as specified. A M E X X T C O [_____]
___ ___ ___ ___
___ ___ ___ ___ ___ ___
c. [d. e.
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___]
___ ___ ___ ___ ___ ___
Electrical a. b. c. Power available to unit starter. Power available to unit control panel. Verify that power disconnect is located within sight of the unit it controls.
A ___ ___
M X X
E ___ ___
T X X
___ ___ ___ ___
___
___
___ ___
Controls a. b. c. Factory startup and checkout complete. Chiller safety/protection devices tested. Chilled water flow switch installed and tested. Chilled water pump interlock installed and tested. Condenser water flow switch installed and tested. Condenser water pump interlock installed and tested.
E X
T X X
___ ___
___ ___ ___ ___
___ ___ ___
___ ___
___ ___
e.
___ ___ ___
___ ___
g.
___ ___ ___
___ ___
i.
___ ___ ___
___ ___
SECTION 23 08 00.00 10
Page 17
123044
Pre-Functional Performance Test Checklist - Cooling Tower For Cooling Tower: Checklist Item Installation a. b. c. d. e. Cooling tower properly piped. Cooling tower fan drive adjusted. A M E X T X C O [_____]
___ ___
___ ___ X ___
___ ___ ___ ___ X X X X ___ ___
Cooling tower makeup water supply piped. ___ ___ Verify makeup control valve shutoff. ___ ___
___ ___ X X ___ ___
Fan lubricated and blade pitch adjusted. ___ ___
Electrical a. b. c. d. e. Power available to tower disconnect.
A ___
M X X
E ___ ___
T X X X X
___ ___ ___ ___ ___ ___ ___ ___
Power available to electric sump heater. ___ Control system interlocks functional. Motor and fan rotation checked. Verify that power disconnect is located within sight of the unit is controls.
___ ___ ___ ___ X ___
___
___
___ ___
Piping a. b. Condenser water treatment functional. All required temperature sensing wells, pressure ports and flow sensors have been installed for performance tests.
E X
T X
C X
O ___
___ ___
___ ___ ___ ___ ___ ___
E X
T ___
C X
O _____
___ ___
SECTION 23 08 00.00 10
Page 18
123044
Pre-Functional Performance Test Checklist - Hot Water Boiler For Boiler: [_____]
Checklist Item Installation a. b. c. d. Boiler hot water piping installed. Boiler makeup water piping installed. Boiler fuel oil piping installed. Boiler gas piping installed. A M E X X X X T C O
___ ___ ___ ___ ___ ___ ___ ___
___ ___ ___ ___ ___ ___ X X X X ___ ___
Startup a. Boiler safety/protection devices, including high temperature burner shut-off, low water cutoff, flame failure, pre- and post-purge, have been tested. Verify that PRV rating conforms to boiler rating. Boiler water treatment system functional. Boiler startup and checkout complete. Combustion efficiency demonstrated.
___ ___ ___
___ ___
b.
___ ___ ___ ___ ___ ___ ___ ___ ___ X X X
X X X ___
___ ___ ___ ___ ___ ___ X ___
c. d. e.
Electrical a. Verify that power disconnect is located within sight of the unit served.
___
___
___ ___
Controls a. Hot water pump interlock installed and tested. Hot water proof-of-flow switch installed and tested Hot water heating controls operational.
___ ___ ___
___ ___
b.
___ ___ ___ ___
X X
X X
___ ___ ___ ___
c.
E X
T ___
C X
O ___
___ ___
SECTION 23 08 00.00 10
Page 19
123044
Pre-Functional Performance Test Checklist - Steam Boiler For Boiler: [_____]
Checklist Item Installation a. b. c. d. Boiler steam piping installed. Boiler makeup water piping installed. Boiler fuel oil piping installed. Boiler gas piping installed. A M E X X X X T X ___ X X C X X X X O ___ ___ ___ ___
___ ___ ___ ___ ___ ___ ___ ___
Startup a. Boiler safety/protection devices, including high temperature burner shutoff, low water cutoff, flame failure, pre and post purge, have been tested. Verify that PRV rating conforms to boiler rating. Boiler feed water system operational. Boiler water treatment system functional. Boiler startup and checkout complete. All steam traps operational. All condensate return pumps operational. Combustion efficiency demonstrated.
___ ___ ___
___ ___
b.
___ ___ ___ ___ ___ ___ ___ ___ X
X X X X X
___ ___ ___ ___ X ___
c. d. e. f. g. h.
___ ___ ___ ___ ___ X
___ ___ X X X ___ ___ ___
___ ___ ___ ___ ___ ___ X ___
Electrical a. Verify that power disconnect is located within sight of the unit served.
___
___
___ ___
E X
T ___
C X
O ___
___ ___
SECTION 23 08 00.00 10
Page 20
123044
Pre-Functional Performance Test Checklist - Steam/Hot Water Converter For Converter: Checklist Item Installation a. b. c. d. Converter steam piping installed. Hot water piping installed. Makeup water piping installed. Vacuum breaker installed on shell of shell and tube unit. A M E X X X T ___ C X O ___ [_____]
___ ___ ___ ___ ___ ___
___ ___ ___ X X ___
___ ___
___
Startup a. b. c. All steam traps operational. All condensate return pumps operational. Converter safety/protection devices tested. Converter startup and checkout complete.
E X
T X X
C X
O ___
___ ___
___ ___ ___
___ ___
___ ___ ___ ___
X X
X X
X X
___ ___
d.
Controls a. Control valves/actuators properly installed. Control valves/actuators operable.
___ ___ ___ ___
X X
___ ___ ___ ___ ___ ___
b.
SECTION 23 08 00.00 10
Page 21
123044
Pre-Functional Performance Test Checklist - Fan Coil Unit For Fan Coil Unit: Checklist Item Installation a. Access doors/removable panels are operable and sealed. Condensate drainage is unobstructed. Fan belt adjusted. A M E T C O [_____]
___ ___ ___ ___ ___ ___
X X X
___ X ___
X X X
___ ___ ___
b. c.
Electrical a. b. c. d. Power available to unit disconnect. Power available to unit control panel. Proper motor rotation verified. Verify that power disconnect is located within sight of the unit it controls. Power available to electric heating coil.
T X X
___ ___ ___ ___ ___ ___
___ ___ ___ ___ X ___
___ ___ ___ ___
___ ___ ___
___ ___
[e.
___ ___ ___
___]
Coils [a. Dual temperature piping properly connected. Chilled water piping properly connected. Hot water piping properly connected.
___ ___ ___ ___ ___ ___
X X X
___ ___ ___] X X ___]
[b. [c.
___ ___ ___]
Controls a. Control valves/actuators properly installed. Control valves/actuators operable. Verify proper location and installation of thermostat.
___ ___ ___ ___
X X
___ ___ ___ X ___ ___
b. c.
___ ___
___ ___ ___
Testing, Adjusting, and Balancing (TAB) a. TAB Report approved.
E X
T ___
C X
O ___
___ ___
SECTION 23 08 00.00 10
Page 22
123044
Pre-Functional Performance Test Checklist - Unit Heater For Unit Heater: Checklist Item Installation [a. [a. Hot water piping properly connected. Steam and condensate piping properly connected. A M E X T C O [_____]
___ ___
___ ___ ___]
___ ___
___]
Electrical a. b. c. Power available to unit disconnect. Proper motor rotation verified. Verify that power disconnect is located within sight of the unit it controls. Power available to electric heating coil.
T X X
___ ___ ___ ___ ___ ___
___ ___ X ___
___ ___ ___ ___ ___ ___
X X
___ ___ ___ ___
d.
Controls a. b. c. Control valves properly installed. Control valves operable. Verify proper location and installation of thermostat.
E X X
___ ___ ___ ___
___ ___ ___ X ___ ___
___ ___
___ ___ ___
E X
T ___
C X
O ___
___ ___
SECTION 23 08 00.00 10
Page 23
123044
Pre-Functional Performance Test Checklist - Exhaust Fan For Exhaust Fan: Checklist Item Installation a. Fan belt adjusted. A M E X T ___ C X O ___ [_____]
___ ___
Electrical a. b. c. Power available to fan disconnect. Proper motor rotation verified. Verify that power disconnect is located within sight of the unit it controls.
T X
___ ___ ___
___ ___ X ___
___ ___ ___ ___
___ ___ ___
___ ___
Controls a. b. c. d. e. Control interlocks properly installed. Control interlocks operable. Dampers/actuators properly installed. Dampers/actuators operable. Verify proper location and installation of thermostat.
T X X
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ X X
___ ___ ___ ___
___ ___ ___ ___ ___ ___
___ ___
___ ___ ___
E X
T ___
C X
O ___
___ ___
SECTION 23 08 00.00 10
Page 24
123044
Pre-Functional Performance Test Checklist - Computer Room Unit For Computer Room Unit: Checklist Item Installation a. b. Access doors are operable and sealed. Condensate drainage is unobstructed and routed to floor drain. Fan belt adjusted. A M E X T ___ C X O ___ [_____]
___ ___
___ ___ ___ ___
X X
X ___
X X
___ ___
c.
Electrical a. b. c. d. Power available to unit disconnect. Proper motor rotation verified. Proper motor rotation verified. Verify that power disconnect is located within sight of the unit it controls. Power available to reheat coils.
A ___ ___ ___
M X X X
E ___
T X
C X X X
O ___ ___ ___
___ ___ ___ ___
___ ___
X X
___
___ ___ X ___]
[e.
___ ___
Coils/Humidifier [a. [a. [b. [b. [c. Chilled water piping properly connected. Refrigerant piping properly connected. Hot water piping properly connected. Steam piping properly connected. Humidifier makeup water connected.
E X X X X X
___ ___ ___ ___ ___ ___ ___ ___ ___ ___
___ ___ ___] X X ___]
___ ___ ___] X X X X ___] ___]
Controls a. b. Control valves operable. Unit control system operable and verified. Verify proper location and installation of thermostat.
E X
T X
___ ___
___ ___
___ ___ ___
___ ___
c.
___ ___
___ ___ ___
Testing, Adjusting, and Balancing (TAB) a. TAB Report submitted.
E X
T ___
C X
O ___
___ ___
SECTION 23 08 00.00 10
Page 25
123044
SECTION 23 08 00.00 10
Page 26
123044
Pre-Functional Performance Test Checklist - HVAC System Controls For HVAC System: Checklist Item Installation a. b. Layout of control panel matches drawings. Framed instructions mounted in or near control panel. Components properly labeled (on inside and outside of panel). Control components piped and/or wired to each labeled terminal strip. EMCS connection made to each labeled terminal strip as shown. Control wiring and tubing labeled at all terminations, splices, and junctions. A M E X T X C O [_____]
___ ___
___ ___
___ ___
___ ___
c.
___ ___
___ ___
d.
___ ___
___ ___
e.
___ ___
___ ___
f.
___ ___
___ ___
Main Power and Control Air a. b. 120 volt AC power available to panel. 20 psig compressed air available to panel. ___ ___ ___ X ___ ___
___ ___
___ ___
Testing, Adjusting, and Balancing (TAB) a. TAB Report submitted.
E X
T ___
C X
O ___
___ ___
SECTION 23 08 00.00 10
Page 27
123044
Pre-Functional Performance Test Checklist - Single Zone Air Handling Unit For Air Handling Unit: Checklist Item Installation a. Inspection and access doors are operable and sealed. Condensate drainage is unobstructed. Fan belt adjusted. A M E T C O [_____]
___ ___ ___ ___ ___ ___
X X X
___ X ___
X X X
___ ___ ___
b. c.
Electrical a. b. c. d. Power available to unit disconnect. Power available to unit control panel. Proper motor rotation verified. Verify that power disconnect is located within sight of the unit it controls. Power available to electric heating coil.
T X X
C X
O ___
___ ___ ___ ___ ___ ___
___ ___ X ___
___ ___ ___ ___
___ ___ ___ ___ ___ ___
X X
___ ___ ___ ___
e.
Coils [a. [a. [c. [c. Chilled water piping properly connected. Refrigerant piping properly connected. Hot water piping properly connected. Steam and condensate piping properly connected.
E X X X
___ ___ ___ ___ ___ ___
___ ___ ___] X X ___]
___ ___ ___]
___ ___
___]
Controls a. Control valves/actuators properly installed. Control valves/actuators operable. Dampers/actuators properly installed. Dampers/actuators operable. Verify proper location and installation of thermostat.
___ ___ ___ ___ ___ ___ ___ ___
X X X X
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___
b. c. d. e.
___ ___
___ ___ ___
Testing, Adjusting, and Balancing (TAB) SECTION 23 08 00.00 10
A Page 28
123044
a.
TAB Report approved.
___ ___
___
___
SECTION 23 08 00.00 10
Page 29
123044
Pre-Functional Performance Test Checklist - Energy Recovery System For Energy Recovery System: Checklist Item Installation a. Recovery system piping installed. A M E X T ___ C X O ___ [_____]
___ ___
Startup a. Startup and checkout complete.
E X
T X
C X
O ___
___ ___
Controls a. Control valves/actuators properly installed. Control valves/actuators operable.
___ ___ ___ ___
X X
___ ___ ___ ___ ___ ___
b.
SECTION 23 08 00.00 10
Page 30
123044
- End of Appendix A -
SECTION 23 08 00.00 10
Page 31
123044
APPENDIX B FUNCTIONAL PERFORMANCE TESTS CHECKLISTS
SECTION 23 08 00.00 10
Page 32
123044
Functional Performance Test - Pump [_____] NOTE: Prior to performing this test, for closed loop systems ensure that the system is pressurized and the make-up water system is operational, or for open loop systems ensure that the sumps are filled to the proper level. 1. Activate pump start using control system commands. a. Verify correct operation in:
HAND__________
OFF__________
AUTO__________
b. Verify pressure drop across strainer: Strainer inlet pressure __________ Strainer outlet pressure _________ psig psig
c. Verify pump inlet/outlet pressure reading, compare to Testing, Adjusting, and Balancing (TAB) Report and pump design conditions. DESIGN Pump inlet pressure psig _________ __________ TAB ACTUAL
__________
Pump outlet pressure psig _________
__________
__________
d. Operate pump at shutoff and at 100 percent of designed flow when all components are in full flow. Plot test readings on pump curve and compare results against readings taken from flow measuring devices. SHUTOFF Pump inlet pressure psig Pump outlet pressure psig Pump flow rate gpm __________ __________ 100 percent
__________ __________ __________
__________
Differential Pressure Transmitter
SETPOINT ________
SECTION 23 08 00.00 10
Page 33
123044
Functional Performance Test (cont) -
Pump [_____]
e. For variable speed pumps, operate pump at shutoff (shutoff to be done in manual on variable speed drive at the minimum rpm that the system is being controlled at) and at minimum flow or when all components are in full by-pass. Plot test readings on pump curve and compare results against readings taken from flow measuring devices. SHUTOFF 100 percent __________ __________ __________ __________ __________
Pump inlet pressure psig Pump outlet pressure psig Pump flow rate gpm
__________ SETPOINT ________
Differential Pressure Transmitter
2. Measure motor amperage each phase and voltage phase to phase and phase to ground for both the full flow and the minimum flow conditions. Compare amperage to nameplate FLA a. Full flow: Nameplate FLA Amperage Voltage Voltage __________ Phase 2__________ Ph1-Ph3__________ Ph2-gnd__________ Phase 3__________ Ph2-Ph3__________ Ph3-gnd__________
Phase 1 __________ Ph1-Ph2 __________ Ph1-gnd __________
b. Minimum flow: Amperage Voltage Voltage Phase 1 __________ Ph1-Ph2 __________ Ph1-gnd __________ Phase 2__________ Ph1-Ph3__________ Ph2-gnd__________ Phase 3__________ Ph2-Ph3__________ Ph3-gnd__________
3.
Note unusual vibration, noise, etc.
___________________________________________________________________________
___________________________________________________________________________
SECTION 23 08 00.00 10
Page 34
123044
Functional Performance Test (cont) - Pump [_____] 4. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Contracting Officer's Representative Design Agency Representative Using Agency's Representative _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________
SECTION 23 08 00.00 10
Page 35
123044
Functional Performance Test - Centrifugal Chiller
[_____]
Note: If water-cooled chiller perform in conjunction with Cooling Tower test. 1. Demonstrate operation of chilled water system in accordance with specifications including the following: Start building air handler to provide load for chiller. Activate controls system chiller start sequence as follows: a. b. Time of day startup program initiates chiller start: ____________ Record outdoor air temperature: ____________
c. Start condenser water pump and establish condenser water flow. Verify chiller condenser water proof-of-flow switch operation._____ d. Start chilled water pump and establish chilled water flow. Verify chiller chilled water proof-of-flow switch operation. ____________ e. Verify control system energizes chiller start sequence.__________
f. Verify chiller senses chilled water temperature above set point and control system activates chiller start. _________________________ g. h. Verify functioning of "soft start" sequence. __________________
Record data in 2, 3 and 4 below on fully load chiller.
i. Shut off air handling equipment to remove load on chilled water system. Verify chiller shutdown sequence is initiated and accomplished after load is removed. _____________________________ j. Restart air-handling equipment one minute after chiller shut down. Verify condenser water pump, cooling tower, and chiller restart sequence. _________________________________________________________
2. Verify chiller inlet/outlet pressure and flow reading, compare to Testing, Adjusting, and Balancing (TAB) Report, chiller design conditions, and chiller manufacturer's performance data. DESIGN Chiller inlet pressure psig Chiller outlet pressure psig Chiller flow GPM __________ __________ TAB REPORT ACTUAL
____________________ ____________________ __________ __________
__________
3. Measure chiller amperage each phase and voltage phase to phase and phase to ground for both the fully loaded condition. Motor F/L AMPS Amperage Phase 1 __________ Phase 2__________ Phase 3_______ _________ Voltage Ph1-Ph2 __________ Ph1-Ph3__________ Ph2-Ph3_______
SECTION 23 08 00.00 10
Page 36
123044
Voltage
Ph1-gnd __________
Ph2-gnd__________
Ph3-gnd_______
SECTION 23 08 00.00 10
Page 37
123044
Functional Performance Test (cont) - Centrifugal Chiller 4. a. Record the following information: Outdoor air temperature ________________ Ambient dry bulb temperature ___________ Entering chilled water temperature _____ Leaving chilled water temperature ______ deg deg deg deg F F F F
[_____] Design
__________ __________ __________
b. Calculate chiller load at ambient conditions and compare to chiller rated capacity from manufacturer's literature. Calculated ________ Ton Rated ________ Ton.
5.
Unusual vibration, noise, etc. _______________________________________________________________________ _______________________________________________________________________
6. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications.
Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Contracting Officer's Representative Design Agency Representative Using Agency's Representative _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________
SECTION 23 08 00.00 10
Page 38
123044
Functional Performance Test - Cooling Tower
[_____]
1. Demonstrate operation of the cooling tower in accordance with specification and the following: a. Activate cooling tower fan start using control system command. This should first start condenser water pump, establish flow, delay fan start, as specified, to equalize flow in distribution basin and sump. Verify fan start after timed delay._____________________________________ b. After chiller startup, control system should modulate bypass valve and two-speed fan motor to maintain condenser water set point. Verify function of bypass valve under varying loads. __________________ c. d. Verify cooling tower interlock with chiller._____________________
Verify makeup water float valve is functioning. ___________________
e. Activate chemical treatment feed valve, verify makeup of chemical treatment system, pump, and controls.______________________________ f. Record the following: Entering water temperature _____ deg F Leaving water temperature: _____ deg F Measured water flow: _____ gpm Entering air wet bulb temperature: _____ deg F 2. Compare results with test results from cooling tower specification test. 3. a. Stop all building cooling equipment so that cooling tower pumps stop. Observe tower for at least 15 minutes and verify no overflow occurs___________. b. Start cooling tower pumps in hand and observe pumps for air binding/cavitation , none allowed __________. 4.Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Contracting Officer's Representative Design Agency Representative Using Agency's Representative SECTION 23 08 00.00 10 _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ Page 39
123044
SECTION 23 08 00.00 10
Page 40
123044
Functional Performance Test Checklist - VAV Terminals The Contracting officer will select VAV terminals to be spot-checked during the functional performance test. The number of terminals selected shall not exceed 10 percent. 1. Functional Performance Test: Contractor shall demonstrate operation of selected VAV boxes in accordance with specifications including the following:
a.
Cooling only VAV boxes:
(1) Verify VAV box response to room temperature set point adjustment. Turn thermostat to 5 degrees F below ambient and measure maximum airflow. Turn thermostat to 5 degrees F above ambient and measure minimum airflow. Setting Measured Design Maximum flow [______] [_____] [_____] cfm Minimum flow [______] [_____] [_____] cfm
b.
Cooling with reheat VAV boxes:
(1) Verify VAV box response to room temperature set point adjustment. Turn thermostat to 5 degrees F above ambient and measure maximum airflow. Turn thermostat to 5 degrees F below ambient and measure minimum airflow. Setting [______] [______] Measured [_____] [_____] Design [_____] cfm [_____] cfm
Maximum flow Minimum flow
(2) Verify reheat coil operation range (full closed to full open) by turning room thermostat 5 degrees F above ambient _______. With heating water system and boiler in operation providing design supply hot water temperature record the following: Design HW supply temperature______ deg Actual HW supply temperature______ deg AHU supply air temperature______ deg F VAV supply air temperature______ deg F Calculate coil capacity and compare to Design ______ BTU/hr F F
design: Actual _____BTU/hr
SECTION 23 08 00.00 10
Page 41
123044
Functional Performance Test Checklist (cont)- VAV Terminals c. Parallel Fan powered VAV boxes: (1) Verify VAV box responses to call for heating via set point adjustment. Change from cooling set point to heating set point. Verify cooling damper closes to minimum position, blower fan energizes according to sequence of operation, and upon further drop in space temperature, heating coil activation. __________ With heating water system in operation providing design supply hot water temperature record the following: Design HW supply temperature______ deg Actual HW supply temperature______ deg AHU supply air temperature______ deg F VAV supply air temperature______ deg F Calculate coil capacity and compare to Design ______ BTU/hr F F
design: Actual _____BTU/hr
(2) Check primary air damper maximum/minimum flow settings and compare to actual measured flows. Setting [______] [______] Measured [_____] [_____] Design [_____] cfm [_____] cfm
Maximum flow Minimum flow
(3) Check blower fan flow. [_____] cfm (4) Verify free operation of fan backdraft damper (insure no primary air is being discharged into plenum space). _____________________________________________________________________________
d.
Series Fan Powered VAV boxes
(1) Ensure VAV fan starts prior to AHU fan (2) Verify VAV box response to sensor call for heating via set point adjustment. Change from cooling set point to heating set point. Verify cooling damper closes to minimum position and upon further drop in space temperature, heating coil activation. With heating water system and boiler in operation providing design supply hot water temperature record the following: Design HW supply temperature______ deg F Actual HW supply temperature______ deg F AHU supply air temperature______ deg F VAV supply air temperature______ deg F Calculate coil capacity and compare to design: Design ______ BTU/hr Actual _____BTU/hr (3) Check primary air damper maximum/minimum flow settings and compare to actual measured flows. Setting [______] Measured [_____] Design [_____] cfm Page 42
Maximum flow
SECTION 23 08 00.00 10
123044
Minimum flow
[______]
[_____]
[_____] cfm
SECTION 23 08 00.00 10
Page 43
123044
Functional Performance Test Checklist (cont)- VAV Terminals (4) Verify that minimal primary air is discharging into the plenum space when in full cooling mode. (5) Verify that no plenum air is being induced from the plenum space into the supply air during full cooling by measuring supply air temperature and comparing to primary air temperature Primary air temp Supply air temp _____ deg F _____ deg F
2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date ___________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________
Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Contracting Officer's Representative Design Agency Representative Using Agency's Representative
SECTION 23 08 00.00 10
Page 44
123044
Functional Performance Test Checklist - Variable Volume Air Handling Unit For Air Handling Unit: [_____]
1. Functional Performance Test: Contractor shall verify operation of air handling unit in accordance with specification including the following: a. Ensure that a slight negative pressure exists on inboard side of the outside air dampers throughout the operation of the dampers. Modulate OA, RA, and EA dampers from fully open to fully closed positions__________. b. The following shall be verified [supply fan operating][supply and return fans operating] mode is initiated: (1) All dampers in normal position prior to fan start___________. (2) All valves in normal position prior to fan start____________. (3) System safeties allow start if safety conditions are met.____ (4) VAV fan controller shall "soft-start" fan. __________________ (5) Modulate all VAV boxes to minimum air flow and verify that the static pressure does not exceed the high static pressure shutdown setpoint_____________. (6) Return all VAV boxes to auto _______________. c. Occupied mode of operation - economizer de-energized. (1) Outside air damper at minimum position. _____________________ (2) Return air damper open. _____________________________________ (3) Relief air damper [at minimum position] [closed]. ___________ (4) Chilled water control valve modulating to maintain leaving air temperature set point. Setpoint _______deg F Actual _____deg F (5) Fan VAV controller receiving signal from duct static pressure sensor and modulating fan to maintain supply duct static pressure set point. Setpoint _______inches-wg Actual _____inches-wg d. Occupied mode of operation - economizer energized.
(1) Outside air damper modulated to maintain mixed air temperature set point. Setpoint _______deg F, Actual _____deg F, Outside air damper position ________%. (2) Relief air damper modulates with outside air damper according to sequence of operation. Relief air damper position_____________%. (3) Chilled water control valve modulating to maintain leaving air temperature set point. Setpoint _______deg F Actual _____deg F (4) Hot water control valve modulating to maintain leaving air SECTION 23 08 00.00 10 Page 45
123044
temperature set point. Setpoint _______deg F Actual _____deg F
SECTION 23 08 00.00 10
Page 46
123044
Functional Performance Test Checklist (cont) - Variable Volume Air Handling Unit (5) Fan VAV controller receives signal from duct static pressure sensor and modulates fan to maintain supply duct static pressure set point. Setpoint inches-wg________________ Actual inches-wg___________ e. Unoccupied mode of operation (1) Observe fan starts when space temperature calls for heating and/or cooling. _________ Note: This does not apply to series boxes. (2) All dampers in normal position. _____________________________ (3) Verify space temperature is maintained as specified in sequence of operation. _______________ f. The following shall be verified when the [supply fan off][supply and return fans off] mode is initiated: (1) All dampers in normal position. _____________________________ (2) All valves in normal position. ______________________________ (3) Fan de-energizes. ___________________________________________ g. Verify the chilled water coil control valve operation by setting all VAV's to maximum and minimum cooling. Max Cooling Supply air temp. _____ deg F Verify cooling valve operation_______.
Min cooling Supply air temp. _____ deg F Verify cooling valve operation_______.
h. Verify safety shut down initiated by low temperature protection thermostat. _________ i. Verify occupancy schedule is programmed into time clock/UMCS________. 2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Design Agency Representative _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________
SECTION 23 08 00.00 10
Page 47
123044
Contracting Officer's Representative Using Agency's Representative
_____________________________ _____________________________
SECTION 23 08 00.00 10
Page 48
123044
Functional Performance Test Checklist - Single Zone Air Handling Unit For Air Handling Unit: [_____]
1. Functional Performance Test: Contractor shall verify operation of air handling unit in accordance with specification including the following: a. Ensure that a slight negative pressure exists on inboard side of the outside air dampers throughout the operation of the dampers. Modulate OA, RA, and EA dampers from fully open to fully closed positions.
a. The following shall be verified when the [supply fan operating] [supply and return fans operating] mode is initiated: (1) All dampers in normal position prior to fan start___________. (2) All valves in normal position prior to fan start____________. (3) System safeties allow start if safety conditions are met. ___ b. Occupied mode of operation - economizer de-energized. (1) Outside air damper at minimum position.______________________ (2) Return air damper open.______________________________________ (3) Relief air damper [at minimum position][closed].____________ (4) Chilled water control valve modulating to maintain space cooling temperature set point. Setpoint _______deg F Actual _____deg F (5) Hot water control valve modulating to maintain space heating temperature set point input from outside air temperature controller. ______ c. Occupied mode of operation - economizer energized.
(1) Outside air damper modulated to maintain mixed air temperature set point. Setpoint _______deg F Actual _____deg F O/A damper position ___________% Return Air Temperature_____deg F Outside Air Temperature _______ deg F (2) Relief air damper modulates with outside air damper according to sequence of operation. Relief air damper position ________% (3) Chilled water control valve modulating to maintain space cooling temperature set point. Setpoint _______deg F Actual _____deg F Return sensor overrides to normal operation. d. Unoccupied mode of operation. (1) Observe fan starts when space temperature calls for heating/cooling ____. (2) All dampers in normal position. _________________________ (3) Verify low limit space temperature is maintained as specified in sequence of operation. ______________________________________
SECTION 23 08 00.00 10
Page 49
123044
Functional Performance Test Checklist (cont) - Single Zone Air Handling Unit e. The following shall be verified when the [supply fan off][supply and return fans off] mode is initiated: (1) All dampers in normal position.______________________________ (2) All valves in normal position._______________________________ (3) Fan de-energizes. ___________________________________________ f. Verify cooling coil and heating coil operation by varying thermostat set point from cooling set point to heating set point and returning to cooling set point________. g. Verify safety shut down initiated by low temperature protection thermostat________. h. Verify occupancy schedule is programmed into time clock/UMCS________. 2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Design Agency Representative Contracting Officer's Representative Using Agency's Representative ____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________
SECTION 23 08 00.00 10
Page 50
123044
Functional Performance Test Checklist - Multi-zone Air Handling Unit For Air Handling Unit: [_____]
1. Functional Performance Test: Contractor shall verify operation of air handling unit in accordance with specification including the following: a. Ensure that a slight negative pressure exists on inboard side of the outside air dampers throughout the operation of the dampers. Modulate OA, RA, and EA dampers from fully open to fully closed positions. b. The following shall be verified when the supply and return fans operating mode is initiated: (1) All dampers in normal position. _____________________________ (2) All valves in normal position. ______________________________ (3) System safeties allow start if safety conditions are met. ___ b. Occupied mode of operation - economizer de-energized. (1) Outside air damper at minimum position. _____________________ (2) Return air damper open. _____________________________________ (3) Relief air damper [at minimum position] [closed]. ___________ (4) Chilled water control valve modulating to maintain cold deck supply air temperature set point. Setpoint ______deg F Actual _____deg F (5) Hot water control valve modulating to maintain hot deck supply air temperature set point input from outside air temperature controller. Setpoint _______deg F Actual _____deg F O/A ________deg F c. Occupied mode of operation - economizer energized. Note outside air and return air temperature sensors may need to be simulated. (1) Outside air damper modulates to maintain mixed air temperature set point. Setpoint _______deg F Actual _____deg F Return Air Temperature _______deg F Outside Air Temperature _______deg F (2) Relief air damper modulates with outside air damper according to sequence of operation.__________________________________________________ (3)Chilled water control valve modulating to maintain cold deck supply air temperature set point. Setpoint ______deg F Actual _____deg F (4)Hot water control valve modulating to maintain hot deck supply air temperature set point input from outside air temperature controller. Setpoint _______deg F Actual _____deg F O/A ______ deg F Return temperature sensors to normal operation.
SECTION 23 08 00.00 10
Page 51
123044
Functional Performance Test Checklist (cont) - Multi-zone Air Handling Unit d. Unoccupied mode of operation note time clock and space temperature sensor may require simulation. (4) Observe fan starts when space temperature calls for heating/cooling. (5) All dampers in normal position. ___________________________ (6) Verify low limit space temperature is maintained as specified in sequence of operation. _____________________________________ e. The following shall be verified when the supply and return fans off mode is initiated: (1) All dampers in normal position. (2) All valves in normal position. ____________________________ _____________________________
(3) Fan de-energizes. __________________________________________ Note: return time clock and space temperature sensors to normal operation. f. Verify zone damper operation by varying zone thermostat set points from cooling set point to heating set point and returning to cooling set point. ________________________________________________________________ g. Verify safety shut down initiated by low temperature protection thermostat. _____________________________________________________________ h. Index room thermostats to full cooling then to full heating. Measure and record cold deck, hot deck, and supply air temperatures and determine damper leakage for a minimum of 2 zones. Cold deck temperature __________ degrees F Hot deck temperature __________ degrees F Zone Zone Zone Zone Zone Zone Zone Zone Zone Zone _______ ____ Supply Air Temperature at Max Cooling _______deg F ____ Supply Air Temperature at Max Heating _______deg F ____Hot Deck Damper leakage at Max cooling _______CFM ____Cold Deck Damper leakage at Max heating _______CFM _______ ____ Supply Air Temperature at Max Cooling _______deg F ____ Supply Air Temperature at Max Heating _______deg F ____Hot Deck Damper leakage at Max cooling _______CFM ____Cold Deck Damper leakage at Max heating _______CFM
i. Verify occupancy schedule is programmed into time clock/UMCS________.
SECTION 23 08 00.00 10
Page 52
123044
Functional Performance Test Checklist (cont) - Multi-zone Air Handling Unit 2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Design Agency Representative Contracting Officer's Representative Using Agency's Representative _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________
SECTION 23 08 00.00 10
Page 53
123044
Functional Performance Test Checklist - Packaged Air Cooled Chiller For Chiller: [_____]
1. Functional Performance Test: Contractor shall demonstrate operation of chilled water system in accordance with specifications including the following: Start building air handler to provide load for chiller. Activate controls system chiller start sequence as follows. a. Start chilled water pump and establish chilled water flow. Verify chiller-chilled water proof-of-flow switch operation. ____________ Record outdoor air temperature. ____________ b. Verify control system energizes chiller start sequence. ________
c. Verify chiller senses chilled water temperature above set point and control system activates chiller start. Setpoint_____deg F Actual_____ deg F d. Verify functioning of "soft start" sequence. ___________________
e. Verify and record chiller data in accordance with 2, 3 and 4 below on fully loaded chiller. f. Shut off air handling equipment to remove load on chilled water system. Verify chiller shutdown sequence is initiated and accomplished after load is removed. ___________________________________________ g. Restart air handling equipment one minute after chiller shut Verify chiller restart sequence. ________________________________
down.
2. Verify chiller inlet/outlet pressure reading, compare to Testing, Adjusting, and Balancing (TAB) Report, chiller design conditions, and chiller manufacturer's performance data. DESIGN Chiller inlet pressure (psig) __________ TAB TEST __________ ACTUAL __________
Chiller outlet pressure Chiller flow
(psig) GPM
__________ __________
__________
__________
__________
__________
3. Verify chiller amperage each phase and voltage phase-to-phase and phase-to-ground. Motor F/L AMPS Amperage Phase 1 __________ Phase 2__________ Phase 3_______ _____ Voltage Voltage Ph1-Ph2 __________ Ph1-Ph3__________ Ph2-Ph3_______ Ph1-gnd __________ Ph2-gnd__________ Ph3-gnd_______
SECTION 23 08 00.00 10
Page 54
123044
Functional Performance Test Checklist (cont) - Packaged Air Cooled Chiller 4. a. Record the following information: Design F F _____degrees F F _____degrees F F _____degrees F
Outdoor air temperature ________________ Ambient dry bulb temperature ___________ Entering chilled water temperature _____ Leaving chilled water temperature ______
degrees degrees degrees degrees
b. Calculate chiller load at ambient conditions and compare to chiller rated capacity from manufacturer's literature. Calculated ________ Ton Rated ________ Ton. 5. Unusual vibration, noise, etc.
___________________________________________________________________________
___________________________________________________________________________ 6. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Design Agency Representative Contracting Officer's Representative Using Agency's Representative _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________
SECTION 23 08 00.00 10
Page 55
123044
Functional Performance Test Checklist - Air Cooled Condensing Unit For Condensing Unit: [_____]
1. Functional Performance Test: Contractor shall demonstrate operation of refrigeration system in accordance with specifications including the following: Start building air handler to provide load for condensing unit. Activate controls system start sequence as follows. a. Start air handling unit. Verify control system energizes condensing unit start sequence. __________________________________________ b. Verify and record data in 2 and 3 below. c. Shut off air handling equipment to verify condensing unit de-energizes. ___________________________________________________________ d. Restart air handling equipment one minute after condensing unit shut down. Verify condensing unit restart sequence. _____________________ 2. Verify condensing unit amperage each phase and voltage phase to phase and phase to ground. Motor Full-Load Amps __________ Amperage Voltage Voltage 3. Phase 1 __________ Ph1-Ph2 __________ Ph1-gnd __________ Phase 2__________ Ph1-Ph3__________ Ph2-gnd__________ Phase 3_______ Ph2-Ph3_______ Ph3-gnd_______
Record the following information: Ambient dry bulb temperature __________ degrees F Suction pressure __________ psig Discharge pressure __________ psig Unusual vibration, noise, etc.
4.
___________________________________________________________________________
___________________________________________________________________________ 5. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist _____________________________ Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Design Agency Representative Contracting Officer's Representative SECTION 23 08 00.00 10 _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ Page 56
123044
Using Agency's Representative
_____________________________
SECTION 23 08 00.00 10
Page 57
123044
Functional Performance Test Checklist - Hot Water Boiler For Boiler: [_____]
1. Functional Performance Test: Contractor shall demonstrate operation of hot water system in accordance with specifications including the following: Start building heating equipment to provide load for boiler. Activate controls system boiler start sequence as follows. a. Start hot water pump and establish hot water flow. Verify boiler hot water proof-of-flow switch operation. ____________________________ Record outdoor air temperature. ____________________________ b. Verify control system energizes boiler start sequence. _________
c. Verify boiler senses hot water temperature below set point and control system activates boiler start. Setpoint_________deg F
2. Verify boiler inlet/outlet pressure reading, compare to Test and Balance (TAB) Report, boiler design conditions, and boiler manufacturer's performance data. DESIGN SYSTEM TEST ACTUAL Boiler inlet water temperature deg F __________ _________ _________ Boiler outlet water temperature deg F __________ _________ _________ Boiler outlet pressure psig __________ _________ _________ Boiler flow rate gpm __________ _________ _________ Flue-gas temperature at boiler outlet deg F _________ _________ Percent carbon dioxide in flue-gas _________ _________ Draft at boiler flue-gas exit inches-wg _________ _________ Stack emission pollutants concentration __________ _________ _________ Fuel type __________ _________ _________ Combustion efficiency __________ _________ _________
3.
Record the following information:
Ambient dry bulb temperature to determine reset schedule_____degrees F Building Entering hot water temperature _____degrees F Building Leaving hot water temperature ____ degrees F 4. Verify temperatures in item 3 are in accordance with the reset schedule. ______________________________________________________________ 5. Verify a. b. c. d. e. f. g. proper operation of boiler safeties. Low water_____ Water flow____ Flame failure____ Pilot failure____ Pre and Post Purge failure____ Pressure relief___ High temperature____ ________________________
6. Shut off building heating equipment to remove load on hot water system. Verify boiler shutdown sequence is initiated and accomplished after load is removed. _______________________________________________________
SECTION 23 08 00.00 10
Page 58
123044
SECTION 23 08 00.00 10
Page 59
123044
Functional Performance Test Checklist (cont) - Hot Water Boiler 7. Unusual vibration, noise, etc.
___________________________________________________________________________
___________________________________________________________________________ 8. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Design Agency Representative Contracting Officer's Representative Using Agency's Representative _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________
SECTION 23 08 00.00 10
Page 60
123044
Functional Performance Test Checklist - Steam Boiler For Boiler: [_____]
1. Functional Performance Test: Contractor shall demonstrate operation of steam heating system in accordance with specifications including the following: Start building heating equipment to provide load for boiler. Activate controls system boiler start sequence as follows. a. Start steam heating system. Verify control system energizes boiler start sequence. __________________________________________________ Record the outdoor air temperature. ______________________________________ b. Verify boiler senses steam pressure below set point and control system activates boiler start. __________________________________________ c. Shut off building heating equipment to remove load on steam heating system. Verify boiler shutdown sequence is initiated and accomplished after load is removed. _____________________________________ d. Verify that water level and makeup water system are operational. _____________________________________________________________________________ 2. Verify boiler inlet/outlet pressure reading, compare to boiler design conditions and manufacturer's performance data.
DESIGN SYSTEM TEST ACTUAL Boiler inlet feedwater temp deg F __________ __________ __________ Boiler outlet pressure psig __________ __________ __________ Flue-gas temperature at boiler outlet deg F __________ __________ Percent carbon dioxide in flue-gas __________ __________ Draft at boiler flue-gas exit inches-wg __________ __________ Stack emission pollutants concentration __________ __________ __________ Fuel type __________ __________ __________ Combustion efficiency __________ __________ __________ 3. Record the following information: Ambient temperature __________ deg F 4. 5. Verify proper operation of boiler safeties.__________________________ Unusual vibration, noise, etc.
___________________________________________________________________________
___________________________________________________________________________ 6. Visually check refractory for cracks or spalling and refractory and tubes for flame impingement._______________________________________________
SECTION 23 08 00.00 10
Page 61
123044
Functional Performance Test Checklist (cont) - Steam Boiler 7. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Design Agency Representative Contracting Officer's Representative Using Agency's Representative _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________
SECTION 23 08 00.00 10
Page 62
123044
Functional Performance Test Checklist - Fan Coil Units The Contracting Officer will select fan coil units to be spot-checked during the functional performance test. The number of terminals shall not exceed 10 percent. Hot water and chilled water systems must be in operation providing design water temperatures. 1. Functional Performance Test: Contractor shall demonstrate operation of selected fan coils in accordance with specifications including the following: a. Cooling only fan coils:
(1) Verify fan coil unit response to room temp set point adjustment. 1. Check blower fan airflow. _____ cfm 2. Check cooling coil water flow. _____ gpm 3. Verify proper operation of cooling water control valve.______ 4. Cooling mode inlet air temperature ______deg F 5. Cooling mode outlet air temperature______deg F 6. Calculate coil sensible capacity and compare to design: Calculated _______BTU/hr Design______BTU/hr b. Cooling/heating fan coils:
(1) Verify fan coil unit response to room temp set point adjustment. 1. Check blower fan airflow. _____ cfm 2. Check cooling coil water flow. _____ gpm 3. Verify proper operation of cooling water control valve. ____ 4. Check cooling mode inlet air temperature. _____deg F 5. Check cooling mode outlet air temperature. _____deg F 6. Calculate cooling coil sensible capacity and compare to design: 7. Calculated _________BTU/hr Design_____BTU/hr 8. Check heating coil water flow. _____ gpm 9. Verify proper operation of heating water control valve. _____ 10. Check heating mode inlet air temperature. _____ deg F 11. Check heating mode outlet air temperature. _____deg F 12. Calculate heating coil capacity and compare to design: Calculated______BTU/hr design_______BTU/hr 2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative ____________________________ _____________________________ ______________________________ ______________________________ _____________________________
SECTION 23 08 00.00 10
Page 63
123044
Design Agency Representative Contracting Officer's Representative Using Agency's Representative
_____________________________ _____________________________ _____________________________
SECTION 23 08 00.00 10
Page 64
123044
Functional Performance Test Checklist - Unit Heaters The Contracting Officer will select unit heaters to be spot-checked during the functional performance test. The number of terminals shall not exceed 10 percent. Hot water systems {for hot water unit heaters} must be in operation and supplying design hot water supply temperature water. 1. Functional Performance Test: of selected unit heaters: Contractor shall demonstrate operation
a. Verify unit heater response to room temperature set point adjustment.___________________________________ b. Check heating mode inlet air temperature. _____ deg F c. Check heating mode outlet air temperature. _____ deg F d. Record manufacturer's submitted fan capacity _____cfm e. Calculate unit heater capacity using manufacturer's fan capacity and recorded temperatures and compare to design. f. Calculated_____BTU/hr Design______BTU/hr 2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Design Agency Representative Contracting Officer's Representative Using Agency's Representative _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________
SECTION 23 08 00.00 10
Page 65
123044
Functional Performance Test Checklist - Steam/Hot Water Converter For Converter: [_____]
1. Functional Performance Test: Contractor shall demonstrate operation of heating system in accordance with specifications including the following: Start building heating equipment to provide load for converter. a. Verify control system energizes. _______________________________
b. Verify converter senses hot water temperature below set point and control system modulates steam valve. ____________________________________ c. Shut off building heating equipment to remove load on heating system. Verify converter steam valve closes after load is removed. ______ 2. Verify converter inlet/outlet pressure reading, compare to converter design conditions and manufacturer's performance data. DESIGN ACTUAL Converter inlet water temp deg F __________ __________ Converter outlet water temp deg F __________ __________ Converter inlet steam pressure psig __________ __________ Determine water flow rate based on pressure drop through converter (GPM)__________ __________ Determine water flow rate with flow measuring device GPM __________ __________ Verify that temperature of water Current Actual is in accordance with outdoor air Setpoint Temperature reset schedule __________ __________
3.
Verify proper operation of converter safeties.
_____________________
4. Check and report unusual vibration, noise, etc. ___________________________________________________________________________ ___________________________________________________________________________ 5. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Design Agency Representative Contracting Officer's Representative ____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________
SECTION 23 08 00.00 10
Page 66
123044
Using Agency's Representative
_____________________________
SECTION 23 08 00.00 10
Page 67
123044
Functional Performance Test Checklist - Computer Room Unit For Computer Room Unit: [_____]
1. Functional Performance Test: Contractor shall verify operation of computer room unit in accordance with specification including the following: a. System safeties allow start if safety conditions are met. ______
b. Verify cooling and heating operation by varying thermostat set point from space set point to space set point plus 10 degrees, space set point minus 10 degrees, and returning to space set point. ________________ c. Verify humidifier operation by varying humidistat set point from space set point to space set point plus 20 percent RH, and returning to space set point. _________________________________________________________________ d. Verify that airflow is within tolerance specified in Section 23 05 93 TESTING, ADJUSTING, AND BALANCING OF HVAC SYSTEMS. _____________________________________________________________________________
2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Design Agency Representative Contracting Officer's Representative Using Agency's Representative ____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________
SECTION 23 08 00.00 10
Page 68
123044
Functional Performance Test Checklist - HVAC Controls For HVAC System: [_____]
The Contracting Officer will select HVAC control systems to undergo functional performance testing. The number of systems shall not exceed 10 percent. Perform this test simultaneously with FPT for AHU or other controlled equipment. 1. Functional Performance Test: Contractor shall verify operation of HVAC controls by performing the Performance Verification Test {PVT} test for that system. Contractor to provide blank PVT test procedures previously done by the controls Contractor. 2. 3. Verify interlock with UMCS system______. Verify all required I/O points function from the UMCS system_____.
4. Certification: We the undersigned have witnessed the Performance Verification Test and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Design Agency Representative Contractor's Officer's Representative Using Agency's Representative _________________________ ___________________________ ___________________________ ___________________________ ___________________________ ___________________________ ___________________________ ___________________________
SECTION 23 08 00.00 10
Page 69
123044
Functional Performance Test Checklist - Energy Recovery System For Energy Recovery System: [_____]
1. Functional Performance Test: Contractor shall demonstrate operation of energy recovery system in accordance with specifications including the following: Start equipment to provide energy source for recovery system. a. b. Verify energy source is providing recoverable energy.____________ Verify recovery system senses available energy and activates.____
2. Verify recovery system inlet/outlet readings, compare to design conditions and manufacturer's performance data.
Design Actual Primary loop inlet temp (degrees F) __________ __________ Primary loop outlet temp (degrees F) __________ __________ Primary loop flow rate [gpm][cfm] __________ __________ Secondary loop inlet temp (degrees F) __________ __________ Secondary loop outlet temp (degrees F) __________ __________ Secondary loop flow rate [gpm][cfm] __________ __________ Primary loop energy BTU/hr __________ __________ Secondary loop energy BTU/hr __________ __________ 3. Verify that recovery system deactivates when recoverable energy is no longer available. __________________________________________________ 4. Check and report unusual vibration, noise, etc. ___________________________________________________________________________ ___________________________________________________________________________ 5. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications. Signature and Date Contractor's Commissioning Specialist Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's TAB Representative Contractor's Controls Representative Design Agency Representative Contractor's Officer's Representative Using Agency's Representative __________________________ ___________________________ ___________________________ ___________________________ ___________________________ __________________________ ___________________________ ___________________________
SECTION 23 08 00.00 10
Page 70
123044
- End of Appendix B -
SECTION 23 08 00.00 10
Page 71
123044
-End of document -- End of Section --
SECTION 23 08 00.00 10
Page 72
123044
*************************************************************************** This specification section applies to MCB Camp Lejeune and MCAS New River projects only. *************************************************************************** SECTION 23 09 23.13 22 BACnet DIRECT DIGITAL CONTROL SYSTEMS FOR HVAC 04/12 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL (AMCA) AMCA 500-D (2007) Laboratory Methods of Testing Dampers for Rating
AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE) ASHRAE 135 (2010; INT 1 2011; Addenda AD & AE 2011) BACnetA Data Communication Protocol for Building Automation and Control Networks
ASME INTERNATIONAL (ASME) ASME B16.5 (2009) Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24 Metric/Inch Standard (2010) Power Piping
ASME B31.1
ASTM INTERNATIONAL (ASTM) ASTM A126 (2004; R 2009) Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus
ASTM B117
INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE) IEEE C62.41.1 (2002; R 2008) Guide on the Surges Environment in Low-Voltage (1000 V and Less) AC Power Circuits (2002) Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits (2002; R 2008) Recommended Practice on Surge Testing for Equipment Connected to Low-Voltage (1000v and less)AC Power SECTION 23 09 23.13 22 Page 1
IEEE C62.41.2
IEEE C62.45
123044
Circuits INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO) ISO 8802-3 (2000) Information Technology Telecommunications and Information Exchange Between Systems - Local and Metropolitan Area Networks - Specific Requirements - Part 3: Carrier Sense Multiple Access with Collision Detection (CSMA/CD)Access Method and Physical Layer Specifications
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA 70 (2011; TIA 11-1; Errata 2011; TIA 11-2; TIA 11-3; TIA 11-4) National Electrical Code (2010; TIA 10-4) National Fire Alarm and Signaling Code (2012) Standard for the Installation of Air Conditioning and Ventilating Systems SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION (SMACNA) SMACNA 1966 (2005) HVAC Duct Construction Standards Metal and Flexible, 3rd Edition
NFPA 72
NFPA 90A
UNDERWRITERS LABORATORIES (UL) UL 1449 (2006; Reprint Feb 2011) Surge Protective Devices (2008; Reprint Mar 2010) Specialty Transformers (2001; Reprint Feb 2010) Industrial Control Panels (2007; Reprint Jun 2010) Standard for Energy Management Equipment
UL 506
UL 508A
UL 916
1.2 1.2.1
DEFINITIONS ANSI/ASHRAE Standard 135
ANSI/ASHRAE Standard 135: BACnet - A Data Communication Protocol for Building Automation and Control Networks, referred to as "BACnet". ASHRAE developed BACnet to provide a method for diverse building automation devices to communicate and share data over a network. 1.2.2 BACnet
Building Automation and Control Network; the common name for the communication standard ASHRAE 135. The standard defines methods and protocol for cooperating building automation devices to communicate over a SECTION 23 09 23.13 22 Page 2
123044
variety of LAN technologies. 1.2.3 BACnet/IP
An extension of BACnet, Annex J, defines this mechanism using a reserved UDP socket to transmit BACnet messages over IP networks. A BACnet/IP network is a collection of one or more IP subnetworks that share the same BACnet network number. See also "BACnet Broadcast Management Device". 1.2.4 BACnet Internetwork
Two or more BACnet networks, possibly using different LAN technologies, connected with routers. In a BACnet internetwork, there exists only one message path between devices. 1.2.5 BACnet Network
One or more BACnet segments that have the same network address and are interconnected by bridges at the physical and data link layers. 1.2.6 BACnet Segment
One or more physical segments of BACnet devices on a BACnet network, connected at the physical layer by repeaters. 1.2.7 BBMD
BACnet Broadcast Management Device (BBMD). A communications device, typically combined with a BACnet router. A BBMD forwards BACnet broadcast messages to BACnet/IP devices and other BBMDs connected to the same BACnet/IP network. Every IP subnetwork that is part of a BACnet/IP network must have only one BBMD. See also "BACnet/IP". 1.2.8 BAS
Building Automation Systems, including DDC (Direct Digital Controls) used for facility automation and energy management. 1.2.9 BIBBs
BACnet Interoperability Building Blocks. A collection of BACnet services used to describe supported tasks. BIBBs are often described in terms of "A" (client) and "B" (server) devices. The A device uses data provided by the "B" device, or requests an action from the B device. 1.2.10 BI
BACnet International, formerly two organizations: the BACnet Manufacturers Association (BMA) and the BACnet Interest Group - North America (BIG-NA). 1.2.11 BI/BTL
BACnet International/BACnet Testing Laboratories (Formerly BMA/BTL). The organization responsible for testing products for compliance with the BACnet standard, operated under the direction of BACnet International. 1.2.12 Bridge
Network hardware that connects two or more network (or BACnet internetwork) SECTION 23 09 23.13 22 Page 3
123044
segments at the physical and data link layers. messages. 1.2.13 Broadcast
A bridge may also filter
A message sent to all devices on a network segment. 1.2.14 DADMS
DON Application and Database Management System, (DADMS) is a listing of digital applications approved for purchase and use. 1.2.15 Device
Any control system component, usually a digital controller, that contains a BACnet Device Object and uses BACnet to communicate with other devices. See also "Digital Controller". 1.2.16 Device Object
Every BACnet device requires one Device Object, whose properties represent the network visible properties of that device. Every Device Object requires a unique Object Identifier number on the BACnet internetwork. This number is often referred to as the device instance. 1.2.17 Device Profile
A collection of BIBBs determining minimum BACnet capabilities of a device, defined in ASHRAE 135, Annex L. Standard device profiles include BACnet Operator Workstations (B-OWS), BACnet Building Controllers (B-BC), BACnet Advanced Application Controllers (B-AAC), BACnet Application Specific Controllers (B-ASC), BACnet Smart Actuator (B-SA), and BACnet Smart Sensor (B-SS). Each device used in new construction is required to have a PICS statement listing BIBBs supported and must be tested and listed by BACnet Testing Laboratory (BTL). 1.2.18 Digital Controller
An electronic controller, usually with internal programming logic and digital and analog input/output capability, which performs control functions. In most cases, synonymous with a BACnet device described in this specification. See also "Device". There are different levels of controllers, with varying levels or complexity and flexibility. 1.2.18.1 Terminal Device Controllers
Terminal device controllers typically are controllers with less control features, may have integrated actuators, and may be mounted directly on equipment (with enclosures). 1.2.18.2 Field Controllers
Field controllers typically have a greater capability for input/output and customization, do not have integral actuators, are mounted in an enclosure not on the equipment and are used for equipment such as VAV air handlers. 1.2.18.3 Plant Controllers
Plant Controllers are typically used to control various equipment in SECTION 23 09 23.13 22 Page 4
123044
mechanical rooms such as pumps, heat exchangers, and chillers. 1.2.18.4 Supervisory Controllers
Supervisory Controller is used to coordinate all equipment in a building, input scheduling, and is often used as a connection point for transferring configuration files to the other controllers. 1.2.18.5 Supervisory Building Controller (SBC)
Supervisory Building Controller (SBC) is used to connect the building's DDC system (MS/TP) to Camp Lejeune's EMCS (TC/IP). Depending on approvals and capabilities, the SBC and supervisory controller may be combined into the same piece of hardware. 1.2.19 Direct Digital Control (DDC)
Digital controllers performing control logic. Usually the controller directly senses physical values, makes control decisions with internal programs, and outputs control signals to directly operate switches, valves, dampers, and motor controllers. 1.2.20 DDC System
A distribution network of digital controllers, communication architecture, and user interfaces. A DDC system may include programming, sensors, actuators, switches, relays, factory controls, operator workstations, and various other devices, components, and attributes. 1.2.21 DITSCAP
Department of Defense Information Technology Security Certification and Accreditation Process (DITSCAP). DISCAP and DIACAP are processes that approve IP base equipment that is connected and communicates on the base Ethernet network. All devices using TCP/IP or Ethernet connectivity require prior approval to be listed in the DITSCAP and SSA document. 1.2.22 EMCS
Energy Management & Control System. The EMCS at Camp Lejeune is an enterprise system that actively receives energy and building condition information from multiple sources and provides load shedding, electric metering, alarming, trending, scheduling, set point adjustment and device status of all supervisory building controllers for maintenance personnel. The EMCS receives real time electrical utility pricing data and automatically manages to Camp Lejeune's energy target. The existing Camp Lejeune EMCS is manufactured by Johnson Controls and incorporates the Metasys extended architecture system that communicates over the MRAN. 1.2.23 EMCS Owner
The regional or local user responsible for managing all aspects of the BAS operation, including: network connections, workstation management, submittal review, technical support, control parameters, and daily operation. The BAS Owner for this project is Utility Monitoring & Control (UMAC) Director 1.2.24 Ethernet
A family of local-area-network technologies providing high-speed networking SECTION 23 09 23.13 22 Page 5
123044
features over various media. Base Telephone manages all Ethernet connections to the IP networks. 1.2.25 Firmware
Software programmed into read only memory (ROM), flash memory, electrically erasable programmable read only memory (EEPROM), or erasable programmable read only memory (EPROM) chips. 1.2.26 Gateway
Communication hardware connecting two or more different protocols, similar to human language translators. The Gateway translates one protocol into equivalent concepts for the other protocol. In BACnet applications, a gateway has BACnet on one side and non-BACnet (usually proprietary) protocols on the other side. 1.2.27 Half Router
A device that participates as one partner in a BACnet point-to-point (PTP) connection. Two half-routers in an active PTP connection combine to form a single router. 1.2.28 Hub
A common connection point for devices on a network. 1.2.29 Internet Protocol (IP, TCP/IP, UDP/IP)
A communication method, the most common use is the World Wide Web. At the lowest level, it is based on Internet Protocol (IP), a method for conveying and routing packets of information over various LAN media. Two common protocols using IP are User Datagram Protocol (UDP) and Transmission Control Protocol (TCP). UDP conveys information to well-known "sockets" without confirmation of receipt. TCP establishes "sessions", which have end-to-end confirmation and guaranteed sequence of delivery. 1.2.30 Input/Output (I/O)
Physical inputs and outputs to and from a device, although the term sometimes describes software, or "virtual" I/O. See also "Points". 1.2.31 I/O Expansion Unit
An I/O expansion unit provides additional point capacity to a digital controller. 1.2.32 IP subnet
Internet protocol (IP) identifies individual devices with a 32-bit number divided into four groups from 0 to 255. Devices are often grouped and share some portion of this number. For example, one device has IP address 209.185.47.68 and another device has IP address 209.185.47.82. These two devices share Class C subnet 209.185.47.00 1.2.33 Local-Area Network (LAN)
A communication network that spans a limited geographic area and uses the same basic communication technology throughout. SECTION 23 09 23.13 22 Page 6
123044
1.2.34
MAC Address
Media Access Control address. The physical node address that identifies a device on a Local Area Network. 1.2.35 Master-Slave/Token-Passing (MS/TP)
ISO 8802-3. The standard LAN for BACnet. MSTP uses twisted-pair wiring for relatively low speed and low cost communication (up to 4,000 ft at 76.8K bps). 1.2.36 Native BACnet Device
A device that uses BACnet as its primary, if not only, method of communication with other BACnet devices without intermediary gateways. A system that uses native BACnet devices at all levels is a native BACnet system. 1.2.37 Network
Communication technology for building network data communications. BACnet approved network types are Point to Point (PTP) Ethernet, and MS/TP. BACnet over Internet Protocol is not an approved method for building level controls. 1.2.38 Network Number
A site-specific number assigned to each network segment to identify for routing. This network number must be unique throughout the BACnet internetwork. 1.2.39 Object
The concept of organizing BACnet information into standard components with various associated properties. Examples include analog input objects and binary output objects. 1.2.40 Object Identifier
An object property used to identify the object, including object type and instance. Object Identifiers must be unique within a device. 1.2.41 Object Properties
Attributes of an object. Examples include present value and high limit properties of an analog input object. Properties are defined in ASHRAE 135; some are optional and some are required. Objects are controlled by reading from and writing to object properties. 1.2.42 Peer-to-Peer
Peer-to-peer refers to devices where any device can initiate and respond to communication with other devices. 1.2.43 Performance Verification Test (PVT)
The procedure for determining if the installed BAS meets design criteria prior to final acceptance. The PVT is performed after installation, SECTION 23 09 23.13 22 Page 7
123044
testing, and balancing of mechanical systems. Typically the PVT is performed by the Contractor in the presence of the Government. 1.2.44 PID
Proportional, integral, and derivative control; three parameters used to control modulating equipment to maintain a setpoint. Derivative control is often not required for HVAC systems (leaving "PI" control). 1.2.45 PICS
Protocol Implementation Conformance Statement (PICS), describing the BACnet capabilities of a device. See BACnet, Annex A for the standard format and content of a PICS statement. 1.2.46 Points See also "Input/Output".
Physical and virtual inputs and outputs. 1.2.47 PTP
Point-to-Point protocol connects individual BACnet devices or networks using serial connections. 1.2.48 Repeater
A network component that connects two or more physical segments at the physical layer. 1.2.49 Router
A BACnet router is a component that joins together two or more networks using different LAN technologies. Examples include joining a BACnet Ethernet LAN to a BACnet MS/TP LAN. 1.2.50 Stand-Alone Control
Refers to devices performing equipment-specific and small system control without communication to other devices or computers for physical I/O, excluding outside air and other common shared conditions. Devices are located near controlled equipment, with physical input and output points limited to 64 or less per device, except for complex individual equipment or systems. Failure of any single device will not cause other network devices to fail. BACnet "Smart" actuators (B-SA profile) and sensors (B-SS profile) communicating on a network with a parent device are exempt from stand-alone requirements. 1.2.51 SSAA
System Security Authorization Agreement. The SSAA is a local document authorizing the use of the IP networks on Camp Lejeune. 1.2.52 Supervisory Controller
Supervisory Controller is the upper level controller on the building's MS/TP bus. It provides building wide points, scheduling, and interface with programming tools.
SECTION 23 09 23.13 22
Page 8
123044
1.2.53
Supervisory Building Controller (SBC)
The Supervisory Building Controller is the point of connection between the Camp Lejeune EMCS network (IP) and the building level control network (MS/TP). The hardware at this location, that provides the connection is referred to as the SBC. Since the EMCS network uses the Marine Air-Ground Task Force Regional Area Network (MRAM) Ethernet network using TCP/IP, any equipment connecting to the Camp Lejeune EMCS must be listed in the approved DITSCAP or DIACAP equipment list and must be Marine Corps DADMS listed and approved. [1.3 SUBCONTRACTOR SPECIAL REQUIREMENTS
Perform all work in this section in accordance with the paragraph entitled "Subcontractor Special Requirements" in Section 01 30 00 ADMINISTRATIVE REQUIREMENTS. The paragraph specifies that all contract requirements of this section shall be accomplished directly by a first tier subcontractor. No work required shall be accomplished by a second tier subcontractor.] a. The controls sub-contractor for this project shall be regularly engaged in the design and installation of BACnet DDC systems (for building HVAC systems) similar to the size and scope of this project, shall have been a representative of the proposed control system manufacturer for a minimum of two years, have a staffed office within a 50-mile radius of the project location, and shall have performed design and installation of DDC systems for a minimum of 5 years. The controls sub-contractor shall ensure that their installing electricians have a copy of, read, and understand the mechanical sheets of the contract's design construction drawings, in addition to the control drawings prepared by the sub-contractor. Provide the DDC programming and graphics using Standard English units of measure, not metric. BACnet DIRECT DIGITAL CONTROL SYSTEMS FOR HVAC DESCRIPTION [Remove existing and] [pProvide new BACnet] [and] [modify existing] [ and merge with existing non-BACnet] [and merge with existing BACnet] DDC systems including associated equipment and accessories.[ The existing DDC system is manufactured by Johnson Controls[_____].] Provide a networked DDC system for stand alone control in compliance with the latest revision of the ASHRAE 135 BACnet standard. Include all programming, objects, and service required to meet the sequence of control. Provide BACnet communication between the DDC system and the native BACnet devices furnished with HVAC equipment, and plant equipment including boilers, chillers, and variable frequency drives. Devices provided shall be BACnet Testing Laboratories (BTL) product listing certified. Interface the new DDC system with Camp Lejeune's existing EMCS. Provide a Supervisory Building Controller (SBC) that shall communicate with the field DDC controllers via the MS/TP bus using BACnet, and with the EMCS via the Marine Air-Ground Task Force Regional Area Network (MRAM) Ethernet network using TCP/IP. Provide interface with the existing EMCS including graphic creation, scheduling, alarming, load management scheduling and trending. Authority to Operate/Authority to Connect: Prior approval to communicate on the base MRAN is a requirement on this project. SECTION 23 09 23.13 22 Page 9
b.
1.4 a.
b.
c.
123044
Supervisory Building Controllers (SBC) and any other device communicating on the MRAN without being DADMS listed and approved and approval from the Designated Approving Authority based on DITSCAP or DIACAP efforts will not be permitted. d. Only technicians authorized by the Camp Lejeune utilities department and factory trained on Metasys extended architecture are approved to add, manage or revise data in the EMCS. Authorization shall require a unique username and password managed by the Utilities Department. All equipment listed as being part of the DDC system shall have a defined energy load value and be entered into the base load rolling program. Graphics, naming, trending and overall user views shall be added to the EMCS. All points added shall be consistent with previously installed buildings. Design Requirements Control System Drawings Title Sheet
1.4.1 1.4.1.1
Provide a title sheet for the control system drawing set. Include the project title, project location, contract number, the controls contractor preparing the drawings, an index of the control drawings in the set, and a legend of the symbols and abbreviations used throughout the control system drawings. 1.4.1.2 List of I/O Points
Also known as a Point Schedule, provide for each input and output point physically connected to a digital controller: point name, point description, point type (Analog Output (AO), Analog Input (AI), Binary Output (BO), Binary Input (BI)), point sensor range, point actuator range, point address, BACnet object, associated BIBBS (where applicable), and point connection terminal number. Typical schedules for multiple identical equipment are allowed unless otherwise requested in design or contract criteria. All points shall adhere to the Camp Lejeune standard naming conventions. 1.4.1.3 Control System Components List
Provide a complete list of control system components installed on this project. Include for each controller and device: control system schematic name, control system schematic designation, device description, manufacturer, and manufacturer part number. For sensors, include point name, sensor range, and operating limits. For valves, include body style, Cv, design flow rate, pressure drop, valve characteristic (linear or equal percentage), and pipe connection size. For actuators, include point name, spring or non-spring return, modulating or two-position action, normal (power fail) position, nominal control signal operating range (0-10 volts DC or 4-20 milliamps), and operating limits. 1.4.1.4 Control System Schematics
Provide control system schematics. Typical schematics for multiple identical equipment are allowed unless otherwise requested in design or contract criteria. Include the following: a. b. Location of each input and output device Flow diagram for each piece of HVAC equipment SECTION 23 09 23.13 22 Page 10
123044
c.
Name or symbol for each control system component, such as V-1 for a valve Setpoints, with differential or proportional band values Written sequence of operation for the HVAC equipment Valve and Damper Schedules, with normal (power fail) position HVAC Equipment Electrical Ladder Diagrams
d. e. f.
1.4.1.5
Provide HVAC equipment electrical ladder diagrams. Indicate required electrical interlocks. 1.4.1.6 Component Wiring Diagrams
Provide a wiring diagram for each type of input device and output device. Indicate how each device is wired and powered; showing typical connections at the digital controller and power supply. Show for all field connected devices such as control relays, motor starters, actuators, sensors, and transmitters. 1.4.1.7 Terminal Strip Diagrams
Provide a diagram of each terminal strip. Indicate the terminal strip location, termination numbers, and associated point names. 1.4.1.8 BACnet Communication Architecture Schematic
Provide a schematic showing the project's entire BACnet communication network, including addressing used for LANs, LAN devices including routers and bridges, gateways, controllers, workstations, and field interface devices. If applicable, show connection to existing networks. 1.5 SUBMITTALS
Submit detailed and annotated manufacturer's data, drawings, and specification sheets for each item listed, that clearly show compliance with the project specifications. Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for [Contractor Quality Control Approval..][information only.] The following shall be submitted in accordance with Section [01 33 00 SUBMITTAL PROCEDURES][01 33 00.05 20 CONSTRUCTION SUBMITTAL PROCEDURES]: SD-02 Shop Drawings Include the following in the project's control system drawing set: Control system drawings title sheet; G List of I/O Points; G Control System Components List; G Control system schematics; G
SECTION 23 09 23.13 22
Page 11
123044
HVAC Equipment Electrical Ladder diagrams; G Component wiring diagrams; G Terminal strip diagrams; G BACnet communication architecture schematic; G SD-03 Product Data Direct Digital Controllers; G Include BACnet PICS for each controller/device type, including smart sensors (B-SS) and smart actuators (B-SA). BACnet Gateways; G Include BACnet and workstation display information; bi-directional communication ability; compliance with interoperability schedule; expansion capacity; handling of alarms, events, scheduling and trend data; and single device capability (not depending on multiple devices for exchanging information from either side of the gateway). Notebook Computer; G Sensors and Input Hardware; G Output Hardware; G Surge and transient protection; G [Duct smoke detectors; G] [Variable frequency (motor) drives; G] SD-05 Design Data Performance Verification Testing Plan; G Pre-Performance Verification Testing Checklist; G SD-06 Test Reports Performance Verification Testing Report; G SD-07 Certificates Contractor's Qualifications; G SD-09 Manufacturer's Field Reports Pre-PVT Checklist; G SD-10 Operation and Maintenance Data Comply with requirements for data packages in Section [01 78 23 OPERATION AND MAINTENANCE DATA][01 78 24.05 2000 20 FACILITY ELECTRONIC OPERATION AND MAINTENANCE SUPPORT INFORMATION (eOMSI), SECTION 23 09 23.13 22 Page 12
123044
except as supplemented and modified in this specification. BACnet Direct Digital Control Systems, Data Package 4; G Controls System Operators Manuals, Data Package 4; G VFD Service Manuals, Data Package 4; G SD-11 Closeout Submittals DDC Software; G Training documentation; G 1.6 1.6.1 QUALITY ASSURANCE Standard Products
Provide material and equipment that are standard manufacturer's products currently in production and supported by a local service organization. 1.6.2 Delivery, Storage, and Handling
Handle, store, and protect equipment and materials to prevent damage before and during installation according to manufacturer's recommendations, and as approved by the Contracting Officer. Replace damaged or defective items. 1.6.3 Operating Environment
Protect components from humidity and temperature variation, dust, and contaminants. If components are stored before installation, keep them within the manufacturer's limits. 1.6.4 Finish of New Equipment
New equipment finishing shall be factory provided. Manufacturer's standard factory finishing shall be proven to withstand 125 hours in a salt-spray fog test. Equipment located outdoors shall be proven to withstand 3000 hours in a salt-spray fog test. Salt-spray fog test shall be according to ASTM B117, with acceptance criteria as follows: immediately after completion of the test, the finish shall show no signs of degradation or loss of adhesion beyond 0.125 inch on either side of the scratch mark. 1.6.5 Verification of Dimensions
The contractor shall verify all dimensions in the field, and advise the Contracting Officer of any discrepancy before performing work. 1.6.6 Contractor's Qualifications
Submit documentation certifying the controls Contractor performing the work has completed at least three DDC systems installations of a similar design to this project, and programmed similar sequences of operation for at least two years. Submit the name of the technician proposed to make additions/alterations to the EMCS servers. Submit supporting documentation demonstrating their qualifications.
SECTION 23 09 23.13 22
Page 13
123044
1.6.7
Modification of References
The advisory provisions in ASME B31.1 and NFPA 70 are mandatory. Substitute "shall" for "should" wherever it appears and interpret all references to the "authority having jurisdiction" and "owner" to mean the Contracting Officer. 1.6.8 Project Sequence
The control system work for this project shall proceed in the following order: a. Submit and receive approval on the Shop Drawings, Product Data, and Certificates specified under the paragraph entitled "SUBMITTALS." Perform the control system installation work, including all field check-outs and tuning. Provide support to TAB personnel as specified under the paragraph "TEST AND BALANCE SUPPORT." Submit and receive approval of the Controls System Operators Manual specified under the paragraph "CONTROLS SYSTEM OPERATORS MANUALS." Submit and receive approval of the Performance Verification Testing Plan and the Pre-PVT Checklist specified under the paragraph "PERFORMANCE VERIFICATION TESTING." Perform the Performance Verification Testing. Submit and receive approval on the PVT Report. Submit and receive approval on the Training Documentation specified under the paragraph "INSTRUCTION TO GOVERNMENT PERSONNEL"[ and "VFD Service Support"]. Submit at least 30 days before training. Deliver the final Controls System Operators Manuals[ and VFD Service Manuals]. Conduct the Phase I Training[ and VFD on-site/hands-on training]. Conduct the Phase II Training. Submit and receive approval of Closeout Submittals. PRODUCTS DDC SYSTEM
b.
c.
d.
e.
f. g. h.
i.
j. k. l. PART 2 2.1
Provide a networked DDC system for stand-alone control in compliance with the latest revision of the ASHRAE 135 BACnet standard. Include all programming, objects, and services required to meet the sequence of control. Provide BACnet MSTP communications between the DDC system and native BACnet devices furnished with HVAC equipment, and plant equipment such as boilers, and chillers when provided with BACnet MSTP communications. DDC controllers provided shall be certified in the BACnet Testing Laboratories (BTL) Product Listing. BACnet over IP is not permitted.
SECTION 23 09 23.13 22
Page 14
123044
2.1.1
Supervisory Building Controller (SBC)
Provide an SBC that communicates between the DDC system and the Camp Lejeune EMCS server. Provide all necessary hardware, drivers, software, material and equipment which shall allow communication and control between the SBC and the field DDC controllers using BACnet on the MS/TP bus. The SBC shall be capable of upload/download to and from the EMCS server. All SBC information shall transfer back to the EMCS system via the Ethernet TCP/IP level 1 network. All IP addresses and network drops shall be furnished by base telephone. Supervisory Building Controllers (SBC) must be listed and approved on the Marine Corps DADMS and listed in the sites DITSCAP SSAA documents. When the SBC is disconnected from the enterprise system for maintenance, access to the SBC shall be via a laptop computer with Internet Explorer and not require any proprietary licensed software or license key. 2.1.2 Direct Digital Controllers
Direct digital controllers shall be UL 916 rated. 2.1.2.1 I/O Point Limitation
The total number of I/O hardware points used by a single stand-alone digital controller, including I/O expansion units, shall not exceed 64. Place I/O expansion units in the same cabinet as the digital controller. 2.1.2.2 Environmental Limits
Controllers shall be suitable for, or placed in protective enclosures suitable for the environment (temperature, humidity, dust, and vibration) where they are located. 2.1.2.3 Stand-Alone Control
Provide stand-alone digital controllers capable of meeting the complete sequence of operation with and without network connectivity (being connected to the EMCS). 2.1.2.4 Internal Clock
Provide internal clocks for all BACnet Building Controllers (B-BC) and BACnet Advanced Application Controllers (B-AAC) using BACnet time synchronization services. Automatically synchronize system clocks daily from an operator-designated controller. The system shall automatically adjust for daylight saving time. 2.1.2.5 Memory
Provide sufficient memory for each controller to support the required control, communication, trends, alarms, and messages. Protect programs residing in memory with EEPROM, flash memory, or by an uninterruptible power source (battery or uninterruptible power supply). The backup power source shall have capacity to maintain the memory during a 72-hour continuous power outage. Rechargeable power sources shall be constantly charged while the controller is operating under normal line power. Batteries shall be replaceable without soldering. Trend and alarm history collected during normal operation shall not be lost during power outages less than 72 hours long.
SECTION 23 09 23.13 22
Page 15
123044
2.1.2.6
Immunity to Power Fluctuations
Controllers shall operate at 90 percent to 110 percent nominal voltage rating. 2.1.2.7 Transformer
The controller power supply shall be fused or current limiting and rated at 125 percent power consumption. 2.1.2.8 Wiring Terminations
Use screw terminal wiring terminations for all field-installed controllers. Provide field-removable modular terminal strip or a termination card connected by a ribbon cable for all controllers other than terminal units. 2.1.2.9 Input and Output Interface
Provide hard-wired input and output interface for all controllers as follows: a. Protection: Shorting an input or output point to itself, to another point, or to ground shall cause no controller damage. Input or output point contact with sources up to 24 volts AC or DC for any duration shall cause no controller damage. Binary Inputs: Binary inputs shall monitor two state devices.
b. c.
Pulse Accumulation Inputs: Pulse accumulation inputs shall conform to binary input requirements and accumulate pulses at a resolution suitable to the application. Analog Inputs: Analog inputs shall monitor low-voltage (0-10 VDC), current (4-20 mA), or resistance (thermistor or RTD) signals. Binary Outputs: Binary outputs shall have a toggle switch and send a pulsed 24 VDC low-voltage signal for modulation control, or provide a maintained open-closed position for on-off control. For HVAC equipment and plant controllers, provide for manual overrides, either with three-position (on-off-auto) override switches and status lights, or with an adjacent operator display and interface. Where appropriate, provide a method to select normally open or normally closed operation. Analog Outputs: Analog outputs shall send modulating 0-10 VDC or 4-20 mA signals to control output devices. Tri-State Outputs: Tri-State outputs shall provide three-point floating control of terminal unit electronic actuators. Digital Controller Cabinet
d.
e.
f.
g.
2.1.2.10
Provide each digital controller as factory mounted or in a factory fabricated cabinet enclosure. Cabinets located indoors shall protect against dust and have a minimum NEMA 1 rating, except where indicated otherwise. Cabinets located outdoors or in damp environments shall protect against all outdoor conditions and have a minimum NEMA 4 rating. Mechanical rooms that contain steam service or equipment are considered damp environments. Outdoor control panels and controllers must be able to SECTION 23 09 23.13 22 Page 16
123044
withstand extreme ambient conditions, without malfunction or failure, whether or not the controlled equipment is running. If necessary, provide a thermostatically controlled panel heater in freezing locations, and an internal ventilating fan in locations exposed to direct sunlight. Cabinets shall have a hinged lockable door and an offset removable metal back plate, except controllers integral with terminal units, like those mounted on VAV boxes. Provide like-keyed locks for all hinged panels provided and a set of two keys at each panel, with one key inserted in the lock. 2.1.2.11 Main Power Switch and Receptacle
Provide each control cabinet with a main external power on/off switch located inside the cabinet. Also provide each cabinet with a separate 120 VAC duplex receptacle. 2.1.2.12 DSL Modems
DSL modems and Rate Adaptive Asymmetric Digital Subscriber Line (RADSL) modems are provided by the government. Telephone modems are not permitted for any other communication with the DDC system. 2.1.2.13 BACnet Gateways
Provide gateways to connect BACnet to legacy systems, existing non-BACnet devices, and existing non-BACnet DDC controlled plant equipment, only when specifically requested and approved by the Government, and shown on the Government approved BACnet Communication Architecture Schematic. Communication shall be MS/TP. Communication using IP is not permitted. Provide with each gateway an interoperability schedule [Use gateway interoperability schedules shown on design drawings or other project documents], showing each point or event on the legacy side that the BACnet "client" will read, and each parameter that the BACnet network will write to. Describe this interoperability in terms of BACnet services, or Interoperability Building Blocks (BIBBS), defined in ASHRAE 135 Annex K. Provide two-year minimum warranty for each gateway, including parts and labor. The following minimum capabilities are required: a. Gateways shall be able to read and view all readable object properties listed in the interoperability schedule on the non-BACnet network to the BACnet network and vice versa where applicable. Gateways shall be able to write to all writeable object properties listed in the interoperability schedule on the non-BACnet network from the BACnet network and vice versa where applicable. Gateways shall provide single-pass (only one protocol to BACnet without intermediary protocols) translation from the non-BACnet protocol to BACnet and vice versa. Gateways shall meet the requirements of Data Sharing Read Property (DS-RP-B), Data Sharing Write Property (DS-WP-B), Device Management Dynamic Device Binding-B (DM-DDB-B), and Device Management Communication Control (DM-DCC-B) BIBBs, in accordance with ASHRAE 135. Gateways shall include all hardware, software, software licenses, and configuration tools for operator-to-gateway communications. Provide backup programming and parameters on CD media and the ability to SECTION 23 09 23.13 22 Page 17
b.
c.
d.
e.
123044
modify, download, backup, and restore gateway configuration. 2.1.3 Notebook Computer
Provide a notebook computer, complete with the project's installed DDC software, configuration files and, applications database, to fully troubleshoot and program the project's devices. Provide the notebook computer with ballistic nylon carrying case with shoulder strap with all necessary cables and interface hardware needed for setup and communication with the controllers and control system components. At a minimum the notebook computer shall include: Common Access Card reader, a Microsoft XP Professional operating system, processor with capability and speed required by application software, 40 giga-byte hard drive, 512 mega-byte RAM, 2 USB 2.0 ports, 10/100 network interface card, internal V.92 modem, 15-inch display, keyboard, 3-hour battery with charger, 52X internal CD-RW drive with CD creator software, and Microsoft Office bundled software. Provide all original licenses, installation media, documentation, and recovery CDs capable of restoring the original configuration. Provide the manufacturer's 3-year next business day on-site warranty with the Government listed as the warranty owner. Provide a CAC card access port. 2.1.4 2.1.4.1 DDC Software Programming
Provide programming to execute the sequence of operation indicated. Provide all programming, programming software tools, and programming hardware tools to configure and program all controllers. If the laptop computer provided elsewhere is used as a programming tool, provide all necessary accessories for full functionality. All software shall be licensed to Marine Corps Base, Camp Lejeune Complex for unrestricted use on Camp Lejeune Complex and reproduction for use on Camp Lejeune Complex. Software keys and "dongles" are not permitted. Provide sequence of operation routines in simple, easy-to-follow logic with detailed text comments describing what the logic does and how it corresponds to the project's written sequence of operation. a. Graphic-based programming shall use a library of function blocks made from pre-programmed code designed for BAS control. Function blocks shall be assembled with interconnecting lines, depicting the control sequence in a flowchart. If providing a computer with device programming tools as part of the project, graphic programs shall be viewable in real time showing present values and logical results from each function block. Menu-based programming shall be done by entering parameters, definitions, conditions, requirements, and constraints. For line-by-line and text-based programming, declare variable types (local, global, real, integer, etc.) at the beginning of the program. Use descriptive comments frequently to describe the programming. If providing a computer with device programming tools as part of the project, provide a means for detecting program errors and testing software strategies with a simulation tool. Simulation may be inherent within the programming software suite, or provided by physical controllers mounted in a NEMA 1 test enclosure. The test enclosure SECTION 23 09 23.13 22 Page 18
b.
c.
d.
123044
shall contain one dedicated controller of each type provided under this contract, complete with power supply and relevant accessories. 2.1.4.2 Parameter Modification
All writeable object properties, and all other programming parameters needed to comply with the project specification shall be adjustable for devices at any network level, including those accessible with web-browser communication, and regardless of programming methods used to create the applications. 2.1.4.3 Short Cycling Prevention
Provide setpoint differentials and minimum on/off times to prevent equipment short cycling. 2.1.4.4 Equipment Status Delay
Provide an adjustable delay from when equipment is commanded on or off and when the control program looks to the status input for confirmation. 2.1.4.5 Run Time Accumulation
Use the Elapsed Time Property to provide re-settable run time accumulation for each Binary Output Object connected to mechanical loads greater than 1 HP, electrical loads greater than 10 KW, or wherever else specified. 2.1.4.6 Timed Local Override
Provide a non-cumulative adjustable override time for the push of a local override button. 2.1.4.7 Time Synchronization
Provide time synchronization, including adjustments for leap years, daylight saving time, and operator time adjustments. 2.1.4.8 Scheduling
Provide operating schedules as indicated, with equipment assigned to groups. Changing the schedule of a group shall change the operating schedule of all equipment in the group. Groups shall be capable of operator creation, modification, and deletion. Provide capability to view and modify schedules in a seven-day week format. Provide capability to enter holiday and override schedules one full year at a time. 2.1.4.9 Object Property Override
Allow writeable object property values to accept overrides to any valid value. Where specified or required for the sequence of control, the Out Of Service property of Objects shall be modifiable using BACnet's write property service. When documented, exceptions to these requirement are allowed for life, machine, and process safeties. 2.1.4.10 Alarms and Events
Alarms and events shall be capable of having programmed time delays and high-low limits. All alarms/events shall report to the EMCS server. Alarms/events shall be stored within the Site Building Controller (SBC). SECTION 23 09 23.13 22 Page 19
123044
Provide alarms/events in agreement with the point schedule, sequence of operation, and the BAS Owner. At a minimum, provide programming to initiate alarms/events any time a piece of equipment fails to operate, a control point is outside normal range or condition shown on schedules, communication to a device is lost, a device has failed, or a controller has lost its memory. 2.1.4.11 Trending
Provide BACnet trend services capable of trending all object present values set points, and other parameters indicated for trending on project schedules. Trends may be associated into groups, and a trend report may be set up for each group. Trends are stored within a device on the BACnet network, with operator selectable trend intervals from 10 seconds up to 60 minutes. The minimum number of consecutive trend values stored at one time shall be 100 per variable. When trend memory is full, the most recent data shall overwrite the oldest data. The SBC shall upload trends automatically upon reaching 3/4 of the device buffer limit (via Notification_Threshold property), by operator request, or by time schedule for archiving. Archived and real-time trend data shall be available for viewing numerically and graphically for at the workstation and connected notebook computers. 2.1.4.12 Device Diagnostics
Each controller shall have diagnostic LEDs for power, communication, and device fault condition. The DDC system shall recognize and report a non-responsive controller. 2.1.4.13 Power Loss
Upon restoration of power, the DDC system shall perform an orderly restart and restoration of control. 2.1.4.14 Access Control
Provide at least five levels of password protection for operator interfaces. The lowest level only allowing viewing of graphics. The second level allows viewing graphics and changing space temperature setpoints. The third level allows the previous level's capability, plus changing operating schedules. The fourth level allows access to all functions except passwords. The highest level provides all administrator rights and allows full access to all programming, including setting new passwords and access levels. Provide the BAS Owner with the highest level password access. Provide automatic log out if no keyboard or mouse activity is detected after a user-defined time delay. 2.1.4.15 Configuration Tool
Provide the software with the manufacturer's installation CDs and licenses. Licenses shall allow unrestricted use and reproduction for use at the Camp Lejeune Complex. Software shall not require the use of software keys or "dongles" Configure the software according to the DDC system manufacturer's specifications and in agreement with BACnet standards found in ASHRAE 135, Annex L. The software shall permit complete monitoring, modification, and troubleshooting interface with the DDC system. The operator interface with SECTION 23 09 23.13 22 Page 20
123044
the software shall be menu-driven with appropriate displays and menu commands to manipulate the DDC system's objects, point data, operating schedules, control routines, system configuration, trends, alarms, messages, graphics, and reports. Trends shall be capable of graphic display in real time, with variables plotted as functions of time. Each alarmed point shall be capable of displaying its alarm history, showing when it went into alarm, if and when it was acknowledged, and when it went out of alarm. The modification of DDC system parameters and object properties shall be accomplished with "fill in the blank" and/or "point and drag" methods. Modifications shall download to the appropriate controllers at the operator's request. 2.1.4.16 Graphics Software
Provide web-based system graphics viewable on browsers compatible with MS Internet Explorer 6.X or greater using an industry-standard file format such as HTML, BMP, JPEG, or GIF. Graphics for new projects must be consistent with base standards including layout and device naming. Contractor shall install this graphics package on the EMCS Server, bind all points, and demonstrate operability. Graphic displays shall have full-screen resolution when viewed on the workstation and notebook computers. Dynamic data on graphics pages shall refresh within 10 seconds using an Internet connection, or 30 seconds using a dial-up modem connection. Graphics viewing shall not require additional "plug-in" software like Java, Shockwave and Flash applications unless the software is readily available for free over the Internet, and certified for use with Navy Marine Corps Internet (NMCI) personal computers. The graphics shall show the present value and object name for each of the project's I/O points on at least one graphic page. Arrange point values and names on the graphic displays in their appropriate physical locations with respect to the floor plan or equipment graphic displayed. Graphics shall allow the operator to monitor current status, view zone and equipment summaries, use point-and-click navigation between graphic pages, and edit setpoints and parameters directly from the screens. Items in alarm shall be displayed using a different color or other obvious visual indicator. Provide graphics with the following: a. Graphic Types: Provide at least one graphic display for each piece of HVAC equipment, building floor, and controlled zone. Indicate dynamic point values, operating statuses, alarm conditions, and control setpoints on each display. Provide summary pages where appropriate. (1) Building Floor Plans: Provide a floor plan graphic for each of the building's floors [and roof] with dynamic display of space temperature and other important data. If used, indicate and provide links to sub-plan areas. If possible, use the project's electronic drawing files for the graphic backgrounds. Provide clear names for important areas, such as "Main Conference Room." Include room names and numbers where applicable. Include features such as stairwells, elevators, and main entrances. Where applicable, include the mechanical room, HVAC equipment, and control component locations, with corresponding links to the equipment graphics. (2) Sub-plan Areas: Where a building's floor plan is too large to adequately display on the screen, sub-divide the plan into distinct areas, and provide a separate graphic display for each SECTION 23 09 23.13 22 Page 21
123044
area. Provide same level of detail requested in building floor plan section above. (3) HVAC Equipment: Provide a graphic display for each piece of HVAC equipment, such as a fan coil unit, VAV terminal, or air handling unit. Equipment shall be represented by a two or three-dimensional drawing. Where multiple pieces of equipment combine to form a system, such as a central chiller plant or central heating plant, provide one graphic to depict the entire plant. Indicate the equipment, piping, ductwork, dampers, and control valves in the installed location. Include labels for equipment, piping, ductwork, dampers, and control valves. Show the direction of air and water flow. Include dynamic display of applicable object data with clear names in appropriate locations. (4) Sequence of Operation: Provide a graphic screen displaying the written out full sequence of operation for each piece of HVAC equipment. Provide a link to the sequence of operation displays on their respective equipment graphics.[ Include dynamic real-time data within the text for setpoints and variables.] b. Graphic Title: page. Provide a prominent, descriptive title on each graphic
c.
Dynamic Update: When the workstation is on-line, all graphic I/O object values shall update with change-of-value services, or by operator selected discrete intervals. Graphic Linking: Provide forward and backward linking between floor plans, sub-plans, and equipment. Graphic Editing: Provide installed software to create, modify, and delete the DDC graphics. Include the ability to store graphic symbols in a symbol directory and import these symbols into the graphics. Dynamic Point Editing: Provide full editing capability for deleting, adding, and modifying dynamic points on the graphics. SENSORS AND INPUT HARDWARE
d.
e.
f.
2.2
Coordinate sensor types with the BAS Owner to keep them consistent with existing installations. 2.2.1 Field-Installed Temperature Sensors Avoid
Where feasible, provide the same sensor type throughout the project. using transmitters unless absolutely necessary. 2.2.1.1 Thermistors
Precision thermistors may be used in applications below 200 degrees F. Sensor accuracy over the application range shall be 0.36 degree F or less between 32 to 150 degrees F. Stability error of the thermistor over five years shall not exceed 0.25 degrees F cumulative. A/D conversion resolution error shall be kept to 0.1 degrees F. Total error for a thermistor circuit shall not exceed 0.5 degrees F.
SECTION 23 09 23.13 22
Page 22
123044
2.2.1.2
Resistance Temperature Detectors (RTDs)
Provide RTD sensors with platinum elements compatible with the digital controllers. Encapsulate sensors in epoxy, series 300 stainless steel, anodized aluminum, or copper. Temperature sensor accuracy shall be 0.1 percent (1 ohm) of expected ohms (1000 ohms) at 32 degrees F. Temperature sensor stability error over five years shall not exceed 0.25 degrees F cumulative. Direct connection of RTDs to digital controllers without transmitters is preferred. When RTDs are connected directly, lead resistance error shall be less than 0.25 degrees F. The total error for a RTD circuit shall not exceed 0.5 degrees F. Allow an additional 0.5 percent accuracy for averaging sensors. 2.2.1.3 a. Temperature Sensor Details
Room Type: Provide the sensing element components within a decorative protective cover suitable for surrounding decor. [Provide room temperature sensors with timed override button, setpoint adjustment lever, digital temperature display.] Provide a communication port for a portable operator interface like a notebook computer or PDA. Duct Probe Type: Ensure the probe is long enough to properly sense the air stream temperature. Duct Averaging Type: Continuous averaging sensors shall be one foot in length for each 4 square feet of duct cross-sectional area, and a minimum length of 6 feet. Pipe Immersion Type: Provide minimum three-inch immersion. Provide each sensor with a corresponding pipe-mounted sensor well, unless indicated otherwise. Sensor wells shall be stainless steel when used in steel piping, and brass when used in copper piping. Provide the sensor well with a heat-sensitive transfer agent between the sensor and the well interior. Outside Air Type: Provide the sensing element on the building's north side with a protective weather shade that positions the sensor approximately 3 inches off the wall surface, does not inhibit free air flow across the sensing element, and protects the sensor from snow, ice, and rain. Transmitters
b.
c.
d.
e.
2.2.2
Provide transmitters with 4 to 20 mA or 0 to 10 VDC linear output scaled to the sensed input. Transmitters shall be matched to the respective sensor, factory calibrated, and sealed. Size transmitters for an output near 50 percent of its full-scale range at normal operating conditions. The total transmitter error shall not exceed 0.1 percent at any point across the measured span. Supply voltage shall be 12 to 24 volts AC or DC. Transmitters shall have non-interactive offset and span adjustments. For temperature sensing, transmitter drift shall not exceed 0.03 degrees F a year. 2.2.2.1 Relative Humidity Transmitters
Provide transmitters with an accuracy equal to plus or minus 3 [2] [5] percent from 0 to 90 percent scale, and less than one percent drift per year. Sensing elements shall be the polymer type.
SECTION 23 09 23.13 22
Page 23
123044
2.2.2.2
Pressure Transmitters
Provide transmitters integral with the pressure transducer. 2.2.3 Current Transducers Current switches
Provide current transducers to monitor motor amperage. may be used to indicate on/off status. [2.2.4 Pneumatic to Electric Transducers
Pneumatic to electronic transducers shall convert a 0 to 20 psig signal to a proportional 4 to 20 mA or 0 to 10 VDC signal (operator scaleable). Supply voltage shall be 24 VDC. Accuracy and linearity shall be 1.0 percent or better. ]2.2.5 Air Quality Sensors
Provide power supply for each sensor. 2.2.5.1 CO2 Sensors
Provide photo-acoustic type CO2 sensors with integral transducers and linear output. The devices shall read CO2 concentrations between 0 and 2000 ppm with full scale accuracy of at least plus or minus 100 ppm. 2.2.5.2 Air Quality Sensors
Provide full spectrum air quality sensors using a hot wire element based on the Taguchi principle. The sensor shall monitor a wide range of gaseous volatile organic components common in indoor air contaminants like paint fumes, solvents, cigarette smoke, and vehicle exhaust. The sensor shall automatically compensate for temperature and humidity, have span and calibration potentiometers, operate on 24 VDC power with output of 0-10 VDC, and have a service rating of 32 to 140 degrees F and 5 to 95 percent relative humidity. 2.2.6 2.2.6.1 Input Switches Timed Local Overrides
Provide buttons or switches to override the DDC occupancy schedule programming for each major building zone during unoccupied periods, and to return HVAC equipment to the occupied mode. This requirement is waived for zones clearly intended for 24 hour continuous operation. 2.2.7 Freeze Protection Thermostats
Provide special purpose thermostats with flexible capillary elements 20 feet in length for coil face areas up to 40 square feet. Provide additional thermostats for larger coils. Provide switch contacts rated for the respective motor starter's control circuit voltage. Include auxiliary contacts for the switch's status condition. A freezing condition at any 18-inch increment along the sensing element's length shall activate the switch. The thermostat shall be equipped with a manual push-button reset switch so that when tripped, the thermostat requires manual resetting before the HVAC equipment can restart.
SECTION 23 09 23.13 22
Page 24
123044
2.2.8
Air Flow Measurement Stations
Air flow measurement stations shall have an array of velocity sensing elements and straightening vanes inside a flanged sheet metal casing. The velocity sensing elements shall be the RTD or thermistor type, traversing the ducted air in at least two directions. The air flow pressure drop across the station shall not exceed 0.1 inch water gage at a velocity of 2,000 fpm. The station shall be suitable for air flows up to 2500 fpm, and a temperature range of 0 to 140 degrees F. The station's measurement accuracy over the range of 125 to 2,500 fpm shall be plus or minus 3 percent of the measured velocity. Station transmitters shall provide a linear, temperature-compensated 4 to 20 mA or 0 to 10 VDC output. The output shall be capable of being accurately converted to a corresponding air flow rate in cubic feet per minute. Transmitters shall be a 2-wire, loop powered device. The output error of the transmitter shall not exceed 0.5 percent of the measurement. 2.2.9 Air Flow Measurement For Terminal Devices
Air flow measurement for terminal devices such as variable air volume boxes, with or without fan power shall have an array of pressure sensing elements that sense total pressure and static pressure. The flow measurement shall be integral to the device controller and shall be by differential pressure sensor. The air flow shall measure flows down to 300 fpm with an accuracy of 5 percent of reading. 2.2.10 Energy Metering
Provide energy meters to collect steam and water consumption, and hot water solar collector generation for the facility and report to the EMCS database. 2.2.10.1 Steam Meters
Steam meters shall be the vortex type, with pressure compensation, a minimum turndown ratio of 10 to 1. Output signal shall be 4-20 ma, pulsed, or BACnet (MS/TP), all compatible with installed DDC system. 2.2.10.2 Water meters
Water meters 1" and smaller shall be positive displacement nutating disk. Water meters larger than 1" shall be compound type. Output signal shall be 4-10 ma, pulse, or BACnet(MS/TP). 2.2.10.3 Hot Water Solar Collector Meters
Meters for hot water solar collectors may be an integrated BTU meter with a BACnet output or may be a combination of temperature sensors and water flow meter monitored by a DDC controller with the DDC system calculating the BTU transfer. Water flow can be measured by orifice or venturi meter selected for the anticipated system flow rate. Temperature sensors shall be placed in both the supply to and the return from the solar collector array. 2.3 2.3.1 OUTPUT HARDWARE Control Dampers
Provide factory manufactured aluminum blade/galvanized steel frame dampers where indicated. Control dampers shall comply with SMACNA 1966 except as modified or supplemented by this specification. Published damper leakage SECTION 23 09 23.13 22 Page 25
123044
rates and respective pressure drops shall have been verified by tests in compliance with AMCA 500-D requirements. Provide damper assembly frames constructed of 13 gauge minimum thickness galvanized steel channels with mitered and welded corners. Damper axles shall be 0.5 inches minimum diameter plated steel rods supported in the damper frame by stainless steel or bronze bearings. Blades mounted vertically shall be supported by thrust bearings. Dampers shall be rated for not less than 2000 fpm air velocity. The pressure drop through each damper when full-open shall not exceed 0.04 inches water gage at 1000 fpm face velocity. Damper assemblies in ductwork subject to above 3-inch water gauge static air pressure shall be constructed to meet SMACNA Seal Class "A" construction requirements. Provide the damper operating linkages outside of the air stream, including crank arms, connecting rods, and other hardware that transmits motion from the damper actuators to the dampers, shall be adjustable. Additionally, operating linkages shall be designed and constructed to have a 2 to 1 safety factor when loaded with the maximum required damper operating force. Linkages shall be brass, bronze, galvanized steel, or stainless steel. Provide access doors or panels in hard ceilings and walls for access to all concealed damper operators and damper locking setscrews. For field-installed control dampers, a single damper section shall have blades no longer than 48 inches and no higher than 72 inches. The maximum damper blade width shall be 12 inches. Larger sized dampers shall be built using a combination of sections. Frames shall be at least 2 inches wide. Flat blades shall have edges folded for rigidity. Blades shall be provided with compressible gasket seals along the full length of the blades to prevent air leakage when closed. The damper frames shall be provided with jamb seals to minimize air leakage. Seals shall be suitable for an operating temperature range of minus 40 degrees F to 200 degrees F. The leakage rate of each damper when full-closed shall be no more than 2 cfm per sq. foot of damper face area at 1.0 inches water gage static pressure. 2.3.2 2.3.2.1 Control Valves Valve Assembly
Valve bodies shall be designed for 125 psig minimum working pressure or 150 percent of the operating pressure, whichever is greater. Valve stems shall be Type 300 series stainless steel. Valve leakage ratings shall be 0.01 percent of rated Cv value. Class 125 copper alloy valve bodies and Class 150 steel or stainless steel valves shall meet the requirements of ASME B16.5. Cast iron valve components shall meet the requirements of ASTM A126 Class B or C. 2.3.2.2 Butterfly Valves
Butterfly valves shall be the threaded lug type suitable for dead-end service and for modulation to the fully-closed position, with stainless steel shafts supported by bearings, non-corrosive discs geometrically SECTION 23 09 23.13 22 Page 26
123044
interlocked with or bolted to the shaft (no pins), and EPDM seats suitable for temperatures from minus 20 degrees F to plus 250 degrees F. Valves shall have a means of manual operation independent of the actuator. 2.3.2.3 Two-Way Valves
Two-way modulating valves shall have an equal percentage characteristic. 2.3.2.4 Three-Way Valves
Three-way valves shall have an equal percentage characteristic. 2.3.2.5 a. Valves for Chilled Water, Condenser Water, and Glycol Fluid Service
Bodies for valves 1-1/2 inches and smaller shall be brass or bronze, with threaded or union ends. Bodies for valves from 2 inches to 3 inches inclusive shall be of brass, bronze, or iron. Bodies for 2 inch valves shall have threaded connections. Bodies for valves from 2-1/2 to 3 inches shall have flanged connections. Internal valve trim shall be brass or bronze, except that valve stems shall be stainless steel. Unless indicated otherwise, provide modulating valves sized for 2 psi minimum and 4 psi maximum differential across the valve at the design flow rate. Valves 4 inches and larger shall be butterfly valves, unless indicated otherwise. Valves for Hot Water Service
b.
c.
d.
2.3.2.6
Valves for hot water service below 250 Degrees F: a. Bodies for valves 1-1/2 inches and smaller shall be brass or bronze, with threaded or union ends. Bodies for valves from 2 inches to 3 inches inclusive shall be of brass, bronze, or iron. Bodies for 2 inch valves shall have threaded connections. Bodies for valves from 2-1/2 to 3 inches shall have flanged connections. Internal trim (including seats, seat rings, modulation plugs, valve stems, and springs) of valves controlling water above 210 degrees F shall be Type 300 series stainless steel. Internal trim for valves controlling water 210 degrees F or less shall be brass or bronze. Valve stems shall be Type 300 series stainless steel. Non-metallic parts of hot water control valves shall be suitable for a minimum continuous operating temperature of 250 degrees F or 50 degrees F above the system design temperature, whichever is higher. Unless indicated otherwise, provide modulating valves sized for 2 psi minimum and 4 psi maximum differential across the valve at the design flow rate. Valves 4 inches and larger shall be butterfly valves, unless indicated otherwise.
b.
c.
d.
e.
f.
SECTION 23 09 23.13 22
Page 27
123044
2.3.2.7
Valves for High Temperature Hot Water Service
Valves for hot water service 250 Degrees F above: a. Valve bodies shall conform to ASME B16.34 Class 300. Valve and actuator combination shall be normally closed. Bodies shall be carbon steel, globe type with welded ends on valves 1 inch and larger. Valves smaller than 1 inch shall have socket-weld ends. Packing shall be virgin polytetrafluoroethylene (PTFE). Internal valve trim shall be Type 300 series stainless steel. Unless indicated otherwise, provide modulating valves sized for 2 psi minimum and 4 psi maximum differential across the valve at the design flow rate. Valves for Steam Service
b. c.
2.3.2.8
The entire body for valves 1-1/2 inches and smaller shall be brass or bronze, with threaded or union ends. Bodies for valves from 2 to 3 inches inclusive shall be of brass, bronze, or carbon steel. Bodies for valves 4 inches and larger shall be carbon steel. Bodies for 2 inch valves shall have threaded connections. Bodies for valves 2-1/2 inches and larger shall have flanged connections. Steam valves shall be sized for [15 psig] [_____] inlet steam pressure with a maximum [13 psi] [_____] differential through the valve at rated flow, except where indicated otherwise. Internal valve trim shall be Type 300 series stainless steel. 2.3.3 Actuators
Provide direct-drive electric actuators for all control applications, except where indicated otherwise. 2.3.3.1 Electric Actuators
Each actuator shall deliver the torque required for continuous uniform motion and shall have internal end switches to limit the travel, or be capable of withstanding continuous stalling without damage. Actuators shall function properly within 85 to 110 percent of rated line voltage. Provide actuators with hardened steel running shafts and gears of steel or copper alloy. Fiber or reinforced nylon gears may be used for torques less than 16 inch-pounds. Provide two-position actuators of single direction, spring return, or reversing type. Provide modulating actuators capable of stopping at any point in the cycle, and starting in either direction from any point. Actuators shall be equipped with a switch for reversing direction, and a button to disengage the clutch to allow manual adjustments. Provide the actuator with a hand crank for manual adjustments, as applicable. Actuators without spring-return may only be used on terminal fan coil units, terminal VAV units, convectors, and unit heaters. Spring return actuators shall be provided on all control dampers and all control valves except terminal fan coil units, terminal VAV units, convectors, and unit heaters; unless indicated otherwise. Each actuator shall have distinct markings indicating the full-open and full-closed position, and the points in-between.
SECTION 23 09 23.13 22
Page 28
123044
2.3.4 2.3.4.1
Output Signal Conversion Electronic-to-Pneumatic Transducers
Electronic to pneumatic transducers shall convert a 4 to 20 mA or 0 to 10 VDC digital controller output signal to a proportional 0 to 20 psig pressure signal (operator scaleable). Accuracy and linearity shall be 1.0 percent or better. [ Transducers shall have feedback circuit that converts the pneumatic signal to a proportional 4 to 20 mA or 0 to 10 VDC signal.] 2.3.5 2.3.5.1 Output Switches Control Relays
Field installed and DDC panel relays shall be double pole, double throw, UL listed, with contacts rated for the intended application, indicator light, and dust proof enclosure. The indicator light shall be lit when the coil is energized and off when coil is not energized. Relays shall be the socket type, plug into a fixed base, and replaceable without tools or removing wiring. Encapsulated "PAM" type relays may be used for terminal control applications. 2.4 2.4.1 ELECTRICAL POWER AND DISTRIBUTION Transformers
Transformers shall conform to UL 506. For control power other than terminal level equipment, provide a fuse or circuit breaker on the secondary side of each transformer. 2.4.2 Surge and Transient Protection
Provide each digital controller with surge and transient power protection. Surge and transient protection shall consist of the following devices, installed externally to the controllers. 2.4.2.1 Power Line Surge Protection
Provide surge suppressors on the incoming power at each controller or grouped terminal controllers. Surge suppressors shall be rated in accordance with UL 1449, have a fault indicating light, and conform to the following: a. The device shall be a transient voltage surge suppressor, hard-wire type individual equipment protector for 120 VAC/1 phase/2 wire plus ground. The device shall react within 5 nanoseconds and automatically reset. The voltage protection threshold, line to neutral, shall be no more than 211 volts. The device shall have an independent secondary stage equal to or greater than the primary stage joule rating. The primary suppression system components shall be pure silicon avalanche diodes. The secondary suppression system components shall be silicon avalanche SECTION 23 09 23.13 22 Page 29
b. c.
d.
e.
f.
123044
diodes or metal oxide varistors. g. The device shall have an indication light to indicate the protection components are functioning. All system functions of the transient suppression system shall be individually fused and not short circuit the AC power line at any time. The device shall have an EMI/RFI noise filter with a minimum attenuation of 13 dB at 10 kHz to 300 MHz. The device shall comply with IEEE C62.41.1 and IEEE C62.41.2, Class "B" requirements and be tested according to IEEE C62.45. The device shall be capable of operating between and plus 122 degrees F. Wiring minus 20 degrees F
h.
i.
j.
k.
2.4.3
Provide complete electrical wiring for the DDC System, including wiring to transformer primaries. Unless indicated otherwise, provide all normally visible or otherwise exposed wiring in conduit. Where conduit is required, control circuit wiring shall not run in the same conduit as power wiring over 100 volts. [Circuits operating at more than 100 volts shall be in accordance with Section 26 20 00, INTERIOR DISTRIBUTION SYSTEM.] Run all circuits over 100 volts in conduit, metallic tubing, covered metal raceways, or armored cable. Use plenum-rated cable for circuits under 100 volts in concealed accessible spaces. Examples of these spaces include HVAC plenums, within walls, above suspended ceilings, in attics, and within ductwork. All wiring in mechanical rooms and mezzanines shall be run in conduit. 2.4.3.1 Power Wiring
The following requirements are for field-installed wiring: a. Wiring for 24 V circuits shall be insulated copper 18 AWG minimum and rated for 300 VAC service. Wiring for 120 V circuits shall be insulated copper 14 AWG minimum and rated for 600 VAC service. Analog Signal Wiring
b.
2.4.3.2
Field-installed analog signal wiring shall be in accordance with manufacturer's installation instructions. Each cable shall be 100 percent shielded and have a 20 AWG drain wire. Each wire shall have insulation rated for 300 VAC service. Cables shall have an overall aluminum-polyester or tinned-copper cable-shield tape. 2.5 2.5.1 FIRE PROTECTION DEVICES Duct Smoke Detectors
Provide duct smoke detectors in HVAC ducts in accordance with NFPA 72 and NFPA 90A, except as indicated otherwise. Provide UL listed or FM approved detectors, designed specifically for duct installation. [Furnish detectors under Section 28 31 76.00 20 INTERIOR FIRE ALARM AND SECTION 23 09 23.13 22 Page 30
123044
MASS NOTIFICATION SYSTEM and install under this section. detectors to the building fire alarm panel.]
Connect new
[Provide photoelectric type detectors. Detectors shall detect both visible and invisible particles of combustion, and shall not be susceptible to undesired operation by changes to relative humidity. Provide each detector with an approved duct housing mounted exterior to the duct, and an integral perforated sampling tube extending across the width of the duct. The detector housing shall have indicator lamps that light when the detector is powered and when the detector is activated. Each detector shall have an integral test port and test switch. Connect new detectors to the building's existing fire alarm control panel. Provide control and power modules required for the operation of the detectors in their own new control unit or integral with the existing fire alarm panel. A ground fault, break, or open condition in the electrical circuitry to any detector or its control or power unit shall cause activation of a trouble signal at the building fire alarm panel. Electrical supervision of wiring used exclusively for air-handling unit shutdown is not required, provided a break in the wiring would cause shutdown of the associated unit. Equipment and devices shall be compatible and operable in all respects with, and shall in no way impair the reliability or operational functions of, the existing fire alarm system. The building's existing fire alarm control panel was manufactured by [_____]. Provide descriptive zone labels at the existing fire alarm panel indicating which new air-handling unit detectors they serve and their location. Label zones modified in order to accomplish the work.] [Provide photoelectric type detectors. Detectors shall detect both visible and invisible particles of combustion, and shall not be susceptible to undesired operation by changes to relative humidity. Provide each detector with an approved duct housing mounted exterior to the duct, and an integral perforated sampling tube extending across the width of the duct. The detector housing shall have indicator lamps that light when the detector is powered and when the detector is activated. Each detector shall have an integral test port and test switch. Provide a 115 VAC power supply unit integral with the detector's duct housing. Provide power to the detector from [the air-handling unit or air-handling unit controls] [the location indicated]. Provide the detectors with a remote alarm indicator device at the location indicated. Activation of a detector shall cause immediate shutdown of the associated air-handling unit and the closing of its dampers and shall activate the remote alarm indicator.] [Provide smoke control systems with a provision for manual operation by means of a key-operated switch to override the duct smoke detector shutdowns. Locate the override switch [adjacent to the building's fire alarm system control panel][as indicated].] 2.6 VARIABLE FREQUENCY (MOTOR) DRIVES
Provide variable frequency drives (VFDs) as indicated. VFDs shall convert 240 or 460 volt (plus or minus 10 percent), three phase, 60 hertz (plus or minus 2Hz), utility grade power to adjustable voltage/frequency, three phase, AC power for stepless motor control from 5 percent to 105 percent of base speed. VFDs shall be UL listed as delivered to the end user. The VFD shall meet the requirements specified in the most current National Electrical Code. Each VFD shall also meet the following: a. The VFD shall use sine coded Pulse Width Modulation (PWM) technology. PWM calculations shall be performed by the VFD microprocessor. SECTION 23 09 23.13 22 Page 31
123044
b.
The VFD shall be capable of automatic control by a remote 4-20 mA 0 to 10 VDC signal, BACnet interface, or manually by the VFD control panel. VFD Quality Assurance
2.6.1
VFDs shall be the manufacturer's current standard production unit with at least 10 identical units successfully operating in the field. 2.6.2 a. VFD Service Support Warranty: Provide the VFDs with a minimum 24-month full parts and labor warranty. The warranty shall start when the contract's HVAC system is accepted by the Government. Include warranty documentation, dates, and contact information with the VFD on-site service manuals. VFD Service Manuals: Provide the VFDs with all necessary installation, operation, maintenance, troubleshooting, service, and repair manuals in English including related factory technical bulletins. Provide the documents factory bound, in sturdy 3-ring binders, or hard bound covers. Provide a title sheet on the outside of each binder indicating the project title, project location, installing contractor, contract number, and the VFD manufacturer, address, and telephone number. Each binder shall include a table of contents and tabbed dividers, with all material neatly organized. The documentation provided shall be specifically applicable to this project, shall be annotated to reflect the actual project conditions, and shall provide a complete and concise depiction of the installed work.[ Provide a storage cabinet on or near the VFD large enough to hold all of the documentation. Have the cabinet's proposed installation site approved in advance by the Contracting Officer. Prominently label the cabinet "VFD OPERATION AND MAINTENANCE MANUALS." Clearly label each manual with the wording "MECHANICAL ROOM COPY - DO NOT REMOVE".] Technical Support: Provide the VFDs with manufacturer's technical telephone support in English, readily available during normal working hours, and free of charge for the life of the equipment. Initial Start-Up: Provide the VFDs with factory-trained personnel for the on-site start-up of the HVAC equipment and associated VFD. The personnel shall be competent in the complete start-up, operation, and repair of the particular model VFD installed. The factory start-up representative shall perform the factory's complete recommended start-up procedures and check-out tests on the VFD. Include a copy of the start-up test documentation with the VFD on-site service manuals. Provide the VFDs with on-site/hands-on training for the user and maintenance personnel. Provide a capable and qualified instructor with minimum two years field experience with the operation and maintenance of similar VFDs. The training shall occur during normal working hours and last not less than 2 hours. Coordinate the training time with the Contracting Officer and the end user. The VFD service manuals shall be used during the training. The contractor shall ensure the manuals are on-site before the start of training. The training shall cover all operational aspects of the VFD. VFD Features
b.
c.
d.
e.
2.6.3
VFDs shall have the following features: SECTION 23 09 23.13 22 Page 32
123044
a.
A local operator control keypad capable of: (1) (2) (3) (4) Remote/Local operator selection with password access. Run/Stop and manual speed commands. All programming functions. Scrolling through all display functions.
b.
Digital display capable of indicating: (1) (2) (3) (4) (5) (6) VFD status. Frequency. Motor RPM. Phase current. Fault diagnostics in descriptive text. All programmed parameters.
c.
Standard PI loop controller with input terminal for controlled variable and parameter settings. User interface terminals for remote control of VFD speed, speed feedback, and an isolated form C SPDT relay, which energizes on a drive fault condition. An isolated form C SPDT auxiliary relay which energizes on a run command. A metal NEMA 1 enclosure for indoors, NEMA 4 with heater for outdoors. An adjustable carrier frequency with 16 KHz minimum upper limit. A built in or external line reactor with 3 percent minimum impedance to protect the VFDs DC buss capacitors and rectifier section diodes. Programmable Parameters
d.
e.
f. g. h.
2.6.4
VFDs shall include the following operator programmable parameters: a. b. c. d. e. f. g. Upper and lower limit frequency. Acceleration and Deceleration rate. Variable torque volts per Hertz curve. Starting voltage level. Starting frequency level. Display speed scaling. Enable/disable auto-restart feature. SECTION 23 09 23.13 22 Page 33
123044
h. i. j. k. l. 2.6.5
Enable/disable soft stall feature. Motor overload level. Motor stall level. Jump frequency and hysteresis band. PWM carrier frequency. Protective Features
VFDs shall have the following protective features: a. An electronic adjustable inverse time current limit with consideration for additional heating of the motor at frequencies below 45Hz, for the protection of the motor. An electronic adjustable soft stall feature, allowing the VFD to lower the frequency to a point where the motor will not exceed the full-load amperage when an overload condition exists at the requested frequency. The VFD will automatically return to the requested frequency when load conditions permit. A separate electronic stall at 110 percent VFD rated current, and a separate hardware trip at 190 percent current. Ground fault protection that protects the output cables and motor from grounds during both starting and continuous running conditions. The ability to restart after the following faults: (1) (2) (3) (4) f. Overcurrent (drive or motor). Power outage. Phase loss. Over voltage/Under voltage.
b.
c.
d.
e.
The ability shut down if inadvertently started into a rotating load without damaging the VFD or the motor. The ability to keep a log of a minimum of four previous fault conditions, indicating the fault type and time of occurrence in descriptive text. The ability to sustain 110 percent rated current for 60 seconds The ability to shutdown safely or protect against and record the following fault conditions: (1) Over current (and an indication if the over current was during acceleration, deceleration, or running). Over current internal to the drive. Motor overload at start-up. SECTION 23 09 23.13 22 Page 34
g.
h. i.
(2) (3)
123044
(4) (5) (6) (7) (8) (9) 2.6.6
Over voltage from utility power. Motor running overload. Over voltage during deceleration. VFD over heat. Load end ground fault. Abnormal parameters or data in VFD EEPROM.
Minimum Operating Conditions
VFDs shall be designed and constructed to operate within the following service conditions: a. b. 2.6.7 Ambient Temperature Range, 0 to 120 degrees F. Non-condensing relative humidity to 90 percent. Additional Features
Provide VFDs with the following additional features: a. b. c. BACnet MS/TP communication interface port RFI/EMI filters One spare VFD of each model provided, fully programmed and ready for back-up operation when connected. EXECUTION INSTALLATION
PART 3 3.1
Perform the installation under the supervision of competent technicians regularly employed in the installation of DDC systems. 3.1.1 BACnet Naming and Addressing
Coordinate with the EMCS Owner and provide naming and addressing consistent with existing buildings already loaded on the EMCS server. All DDC controllers shall have a Camp Lejeune unique instance number and all Site Building Controllers shall have a Camp Lejeune unique name. a. MAC Address Every BACnet device shall have an assigned and documented MAC Address unique to its network. For Ethernet networks, document the MAC Address assigned at its creation. For ARCNET or MS/TP, assign from 4 to 128. b. Network Numbering Assign unique numbers to each new network installed on the BACnet internetwork. Provide ability for changing the network number; either by device switches, network computer, or field operator interface. The BACnet internetwork (all possible connected networks) can contain up to SECTION 23 09 23.13 22 Page 35
123044
65,534 possible unique networks. c. Device Object Identifier Property Number Assign unique Device "Object_Identifier" property numbers or device instances for each device on the BACnet internetwork. Provide for future modification of the device instance number; either by device switches, network computer, or field interface. BACnet allows up to 4,194,302 possible unique devices per internetwork. d. Device Object Name Property Text The Device Object Name property field shall support 32 minimum printable characters. Assign unique Device "Object_Name" property names with plain-English descriptive names for each device For example, the Device Object Name for the device controlling the first floor air handler unit at Building AS4035 would be: Name=Air Station.AS4035.First Floor.Air Handling Unit.AHU-1-A e. Object Name Property Text (Other than Device Objects) The Object Name property field shall support 32 minimum printable characters. Assign Object Name properties with plain-English names descriptive of the application. Examples include "Zone 1 Temperature" and "Fan Start/Stop". f. Object Identifier Property Number (Other than Device Objects) Assign Object Identifier property numbers according to design drawings or tables if provided. If not provided, Object Identifier property numbers may be assigned at the Contractor's discretion but must be approved by the Government. In this case they must be documented and unique for like object types within the device. 3.1.2 a. Minimum BACnet Object Requirements Use of Standard BACnet Objects in accordance with existing Camp Lejeune standards For the following points and parameters, use standard BACnet objects, where all relevant object properties can be read using BACnet's Read Property Service, and all relevant object properties can be modified using BACnet's Write Property Service: all device physical inputs and outputs, all set points, all PID tuning parameters, all calculated pressures, flow rates, and consumption values, all alarms, all trends, all schedules, and all equipment and lighting circuit operating status. b. BACnet Object Description Property The Object Description property shall support 32 minimum printable characters. For each object, complete the description property field using a brief, narrative, plain English description specific to the object and project application. For example: "HW Pump 1 Proof." Document compliance, length restrictions, and whether the description is writeable in the device PICS. c. Analog Input, Output, and Value Objects SECTION 23 09 23.13 22 Page 36
123044
Support and provide Description and/or Device_Type text strings matching signal type and engineering units shown on the points list. d. Binary Input, Output, and Value Objects Support and provide Inactive_Text and Active_Text property descriptions matching conditions shown on the points list. e. Calendar Object For devices with scheduling capability, provide at least one Calendar Object with ten-entry capacity. All operators may view Calendar Objects; authorized operators may make modifications from a workstation. Enable the writeable Date List property and support all calendar entry data types. f. Schedule Object Use Schedule Objects for all building system scheduling. All operators may view schedule entries; authorized operators may modify schedules from a workstation. g. Loop Object or Equal Use Loop Objects or equivalent BACnet objects in each applicable field device for PID control. Regardless of program method or object used, allow authorized operators to adjust the Update Interval, Setpoint, Proportional Constant, Integral Constant, and Derivative Constant using BACnet read/write services. 3.1.3 a. Minimum BACnet Service Requirements Command Priorities Use commandable BACnet objects to control machinery and systems, providing the priority levels listed below. If the sequence of operation requires a different priority, obtain approval from the Contracting Officer. Priority Level 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Application
Manual-Life Safety Automatic-Life Safety (User Defined) (User Defined) Critical Equipment Control Minimum On/Off (User Defined) Manual Operator (User Defined) (User Defined) Load Shedding (User Defined) (User Defined) (User Defined) (User Defined) (User Defined)
SECTION 23 09 23.13 22
Page 37
123044
b.
Alarming (1) Alarm Priorities - Coordinate alarm and event notification with the BAS Owner. (2) Notification Class - Enable writeable Priority, Ack Required, and Recipient List properties of Notification Class objects. (3) Event Notification Message Texts - Use condition specific narrative text and numerical references for alarm and event notification.
c.
Updating Displayed Property Values Allow workstations to display property values at discrete polled intervals, or based on receipt of confirmed and unconfirmed Change of Value notifications. The COV increment shall be adjustable by an operator using BACnet services, and polled intervals shall be adjustable at the operator workstation.
3.1.4
Local Area Networks
Obtain Government approval before connecting new networks with existing networks. Network numbers and device instance numbers shall remain unique when joining networks. Do not change existing network addressing without Government approval. See also "BACnet Naming and Addressing". 3.1.5 BACnet Routers, Bridges, and Switches
Provide the quantity of BACnet routers, bridges, and switches necessary for communications shown on the BACnet Communication Architecture schematic. Provide BACnet routers with BACnet Broadcast Message Device (BBMD) capability on each BACnet internetwork communicating across an MS/TP network. Configure each BACnet device and bridge, router, or switch to communicate on its network segment. All switches provided by the contractor shall be approved by base telephone. 3.1.6 a. Wiring Criteria Run circuits operating at more than 100 volts in rigid or flexible conduit, metallic tubing, covered metal raceways, or armored cable. Do not run binary control circuit wiring in the same conduit as power wiring over 100 volts. Where analog signal wiring requires conduit, do not run in the same conduit with AC power circuits or control circuits operating at more than 100 volts. Provide circuit and wiring protection required by NFPA 70. Run all wiring located inside mechanical rooms in conduit. Do not bury aluminum-sheathed cable or aluminum conduit in concrete. Input/output identification: Permanently label each field-installed wire, cable, and pneumatic tube at each end with descriptive text using a commercial wire marking system that fully encircles the wire, cable, or tube. Locate the markers within 2 inches of each termination. Match the names and I/O number to the project's point list. Similarly label all power wiring serving control devices, including the word SECTION 23 09 23.13 22 Page 38
b.
c. d. e. f.
123044
"power" in the label. Number each pneumatic tube every six feet. Label all terminal blocks with alpha/numeric labels. All wiring and the wiring methods shall be in accordance with UL 508A. g. For controller power, provide new 120 VAC circuits, with ground, if not defined on the electrical drawings. Provide each circuit with a dedicated breaker, and run wiring in its own conduit, separate from any control wiring. Connect the controller's ground wire to the electrical panel ground; conduit grounds are not acceptable. Surge Protection: Install surge protection according to manufacturer's instructions. Multiple controllers fed from a common power supply may be protected by a common surge protector, properly sized for the total connected devices. Grounding: Ground controllers and cabinets to a good earth ground as specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Conduit grounding is not acceptable; all grounding shall have a direct path to the building earth ground. Ground sensor drain wire shields at the controller end. The Contractor shall be responsible for correcting all associated ground loop problems. Run wiring in panel enclosures in covered wire track. Accessibility
h.
i.
j.
k. 3.1.7
Install all equipment so that parts requiring periodic inspection, operation, maintenance, and repair are readily accessible. Install digital controllers, data ports, and concealed actuators, valves, dampers, and like equipment in locations freely accessible through access doors. 3.1.8 a. b. Digital Controllers Install as stand alone control devices (see definitions). Locate control cabinets at the locations shown on the drawings. If not shown on the drawings, install in the most accessible space, close to the controlled equipment. Hand-Off-Auto Switches
3.1.9
Wire safety controls such as smoke detectors and freeze protection thermostats to protect the equipment during both hand and auto operation. 3.1.10 Temperature Sensors
Install temperature sensors in locations that are accessible and provide a good representation of sensed media. Installations in dead spaces are not acceptable. Calibrate sensors according to manufacturer's instructions. Do not use sensors designed for one application in a different application. 3.1.10.1 Room Temperature Sensors
Mount the sensors on interior walls to sense the average room temperature at the locations indicated. Avoid locations near heat sources such as copy machines or locations by supply air outlet drafts. Mount the center of the sensor [5 feet above the finished floor][54 inches above the floor to meet SECTION 23 09 23.13 22 Page 39
123044
ADA requirements][at the height[s] indicated]. 3.1.10.2 a. Duct Temperature Sensors
Probe Type: Provide a gasket between the sensor housing and the duct wall. Seal the duct penetration air tight. Seal the duct insulation penetration vapor tight. Averaging Type (and coil freeze protection thermostats): Weave the capillary tube sensing element in a serpentine fashion perpendicular to the flow, across the duct or air handler cross-section, using durable non-metal supports. Prevent contact between the capillary and the duct or air handler internals. Provide a duct access door at the sensor location. The access door shall be hinged on the side, factory insulated, have cam type locks, and be as large as the duct will permit, maximum 18 by 18 inches. For sensors inside air handlers, the sensors shall be fully accessible through the air handler's access doors without removing any of the air handler's internals. Immersion Temperature Sensors
b.
3.1.10.3
Provide thermowells for sensors measuring piping, tank, or pressure vessel temperatures. Locate wells to sense continuous flow conditions. Do not install wells using extension couplings. Where piping diameters are smaller than the length of the wells, provide wells in piping at elbows to sense flow across entire area of well. Wells shall not restrict flow area to less than 70 percent of pipe area. Increase piping size as required to avoid restriction. Provide thermal conductivity material within the well to fully coat the inserted sensor. 3.1.10.4 Outside Air Temperature Sensors
Provide outside air temperature sensors in weatherproof enclosures on the north side of the building, away from exhaust hoods and other areas that may affect the reading. Provide a shield to shade the sensor from direct sunlight. 3.1.11 Energy Meters
Locate energy meters as indicated. Connect each meter output to the DDC system, to measure both instantaneous and accumulated energy usage. 3.1.12 Damper Actuators
Where possible, mount actuators outside the air stream in accessible areas. 3.1.13 Thermometers and Gages
Mount devices to allow reading while standing on the floor or ground, as applicable. 3.1.14 Pressure Sensors
Locate pressure sensors as indicated. 3.1.15 Component Identification Labeling
Using an electronic hand-held label maker with white tape and bold black block lettering, provide an identification label on the exterior of each SECTION 23 09 23.13 22 Page 40
123044
new control panel, control device, actuator, and sensor. Also provide labels on the exterior of each new control actuator indicating the (full) open and (full) closed positions. For labels located outdoors, use exterior grade label tape, and provide labels on both the inside and outside of the panel door or device cover. Acceptable alternatives are white plastic labels with engraved bold black block lettering permanently attached to the control panel, control device, actuator, and sensor. Have the labels and wording approved by the BAS Owner prior to installation. 3.1.16 Network and Telephone Communication Lines
When telephone lines or network connections by the Government are required, provide the Contracting Officer at least 60 days advance notice of need. Provide 1 inch conduit and Cat 5 cable from the Supervisory Building controller (SBC) to the network connection (most likely in the telephone equipment room). 3.2 INTERFACE WITH EXISTING EMCS
Interface the new DDC system with Camp Lejeune's existing EMCS. Obtain Government approval before connecting new DDC system to the EMCS. Any device connected directly to the EMCS must be approved by the Designated Approving Authority by following procedures listed in the DIACAP instruction. Complete installation and programming includes graphic creation, scheduling, alarming, lard management scheduling and trending. The server is located in Building 24: workstations are located at Buildings 1005, 1023, and 1202. Only Johnson Controls factory trained technicians, approved by the EMCS Engineer will be allowed to program the EMCS. 3.3 TEST AND BALANCE SUPPORT
The controls contractor shall coordinate with and provide on-site support to the test and balance (TAB) personnel [specified under Section 23 05 93 TESTING, ADJUSTING AND BALANCING FOR HVAC.] This support shall include: a. On-site operation and manipulation of control systems during the testing and balancing. Control setpoint adjustments for balancing all relevant mechanical systems, including VAV boxes. Tuning control loops with setpoints and adjustments determined by TAB personnel. CONTROLS SYSTEM OPERATORS MANUALS
b.
c.
3.4
Provide five electronic and three printed copies of a Controls System Operators Manual. The manual shall be specific to the project, written to actual project conditions, and provide a complete and concise depiction of the installed work. Provide information in detail to clearly explain all operation requirements for the control system. Provide with each manual: CDs of the project's control system drawings, control programs, data bases, graphics, and all items listed below. Include gateway back-up data and configuration tools where applicable. Provide CDs in jewel case with printed and dated project-specific labels on both the CD and the case. For text and drawings, use Adobe Acrobat or MS Office file types. When approved by the Government, AutoCAD and Visio files are allowed. Give files descriptive English names and organize in SECTION 23 09 23.13 22 Page 41
123044
folders. Provide printed manuals in sturdy 3-ring binders with a title sheet on the outside of each binder indicating the project title, project location, contract number, and the controls contractor name, address, and telephone number. Each binder shall include a table of contents and tabbed dividers, with all material neatly organized. Manuals shall include the following: a. A copy of the as-built control system (shop) drawings set, with all items specified under the paragraph "Submittals." Indicate all field changes and modifications. A copy of the project's mechanical design drawings, including any official modifications and revisions. A copy of the project's approved Product Data submittals provided under the paragraph "Submittals." A copy of the project's approved Performance Verification Testing Plan and Report. Test report shall be a 48 hour trend report verifying all temperature setpoints listed in the sequence of operation. The trend report should be printed from the EMCS server. All systems (AHU's, ERV's, CHWS, HWS) should be part of this section. A copy of the project's approved final TAB Report. Mechanical Contractor (Division 23)). (Added by the
b.
c.
d.
e.
f.
Printouts of all control system programs, including controller setup pages if used. Include plain-English narratives of application programs, flowcharts, and source code. Printouts of all physical input and output object properties, including tuning values, alarm limits, calibration factors, and set points. A table entitled "AC Power Table" listing the electrical power source for each controller. Include the building electrical panel number, panel location, and circuit breaker number. The DDC manufacturer's hardware and software manuals in both print and CD format with printed project-specific labels. Include installation and technical manuals for all controller hardware, operator manuals for all controllers, programming manuals for all controllers, operator manuals for all workstation software, installation and technical manuals for the workstation and notebook, and programming manuals for the workstation and notebook software. A list of qualified control system service organizations for the work provided under this contract. Include their addresses and telephone numbers. A written statement entitled "Technical Support" stating the control system manufacturer or authorized representative will provide toll-free telephone technical support at no additional cost to the Government for a minimum of two years from project acceptance, will be furnished by experienced service technicians, and will be available during normal weekday working hours. Include the toll-free technical support telephone number. A written statement entitled "Software Upgrades" stating software and SECTION 23 09 23.13 22 Page 42
g.
h.
i.
j.
k.
l.
123044
firmware patches and updates will be provided upon request at no additional cost to the Government for a minimum of two years from contract acceptance. Include a table of all DDC system software and firmware provided under this contract, listing the original release dates, version numbers, part numbers, and serial numbers. 3.4.1 Storage Cabinets
In one project mechanical room, provide a wall-mounted metal storage cabinet with hinged doors. Provide cabinets large enough to hold the entire set of Controls System Operators Manuals, and the HVAC operation and maintenance manuals [provided under Division 23 HVAC.] Locate cabinets adjacent to DDC control panels where applicable. Have each cabinet's proposed installation site approved in advance by the Contracting Officer and the BAS Owner. Prominently label each cabinet with the wording "OPERATION AND MAINTENANCE MANUALS." Place one of the three hard copies of the Operators Manual in this cabinet. Prominently label each binder with the wording "MECHANICAL ROOM COPY - DO NOT REMOVE." 3.5 3.5.1 PERFORMANCE VERIFICATION TESTING (PVT) General
The PVT shall demonstrate compliance of the control system work with the contract requirements. The PVT shall be performed by the Contractor and witnessed and approved by the Government. If the project is phased, provide separate testing for each phase. A Pre-PVT meeting to review the Pre-PVT Checklist is required to coordinate all aspects of the PVT and shall include the Contractor's QA representative, the Contractor's PVT administrator, the Contracting Officer's representative, and the EMCS Owner. 3.5.2 Performance Verification Testing Plan
Submit a detailed PVT Plan of the proposed testing for Government approval. Develop the PVT Plan specifically for the control system in this contract. The PVT Plan shall be a clear list of test items arranged in a logical sequence. Include the intended test procedure, the expected response, and the pass/fail criteria for every component tested. The plan shall clearly describe how each item is tested, indicate where assisting personnel are required (like the mechanical contractor), and include what procedures are used to simulate conditions. Include a separate column for each checked item and extra space for comments. Where sequences of operations are checked, insert each corresponding routine from the projects sequence of operation. For each test area, include signature and date lines for the Contractor's PVT administrator, the Contractor's QA representative, the Contracting Officer's representative, and the EMCS Owner to acknowledge successful completion. 3.5.3 PVT Sample Size
Test all central plant equipment, primary air handling unit controllers, and fan coil unit controllers unless otherwise directed. Use the DDC system to verify all VAV boxes are controlling as specified. The Government may require testing of like controllers beyond a statistical sample if sample controllers require retesting or do not have consistent results. The Government may witness all testing, or random samples of PVT items. SECTION 23 09 23.13 22 Page 43
123044
When only random samples are witnessed, the Government may choose which ones. 3.5.4 Pre-Performance Verification Testing Checklist
Submit the following as a list with items checked off once verified. Provide a detailed explanation for any items that are not completed or verified. a. Verify all required mechanical installation work is successfully completed, and all HVAC equipment is working correctly (or will be by the time the PVT is conducted). Verify HVAC motors operate below full-load amperage ratings. Verify all required control system components, wiring, and accessories are installed. Verify the installed control system architecture matches approved drawings. Verify all control circuits operate at the proper voltage and are free from grounds or faults. Verify all required surge protection is installed. Verify the A/C Power Table specified in "CONTROLS SYSTEM OPERATORS MANUALS" is accurate. Verify all DDC network communications with the EMCS function properly, including commanding set points, and load shedding. Verify air handling unit and VAV box coil performance by commanding all valves 100 percent open in both heating and cooling. Record the entering and leaving air temperatures. Record the entering water temperature. This data shall be printed, stored, and saved for future reference. Verify each digital controllers programming is backed up. Verify all wiring, components, and panels are properly labeled. Verify all required points are programmed into devices. Verify all TAB work affecting controls is complete. Verify all valve and actuator zero and span adjustments are set properly. Verify all sensor readings are accurate and calibrated. Verify each control valve and actuator goes to normal position upon loss of power. Provide 48 hours of trend data to verify all systems are functioning as specified. Trend reports will verify control set point adjustment per the temperature re-set schedules (as required by sequence of operation). Provide the following Trends: SECTION 23 09 23.13 22 Page 44
b. c.
d.
e.
f. g.
h.
i.
j. k. l. m. n.
o. p.
q.
123044
(1) Chilled water System: supply temperature (actual), return temperature (actual) (2) Hot Water System: supply temperature (actual), return temperature (actual), supply temperature set point. (3) Air Handling Unit: discharge air temperature set point, return air temperature set point, discharge air temperature (actual), return air temperature (actual), valve command position. (4) VAV Box (10 percent of VAV's): room temperature set point, room temperature (actual), associated AHU discharge air temperature (actual). (5) Energy Recovery Unit: Wheel status, wheel discharge air temperature (actual), wheel discharge air humidity (actual), unit discharge air temperature set point, unit discharge air temperature (actual). (6) Fan Coil Unit: valve command position, room temperature set point, room temperature (actual). r. s. Verify each controller works properly in stand-alone mode. Verify all safety controls and devices function properly, including freeze protection and interfaces with building fire alarm systems. Verify all electrical interlocks work properly. Verify all workstations, notebooks and maintenance personnel interface tools are delivered, all system and database software is installed, and graphic pages are created for each device controlled by the DDC system. Verify the as-built (shop) control drawings are completed. Verify all required alarms are identified at the EMCS server and proper notification is setup for each alarm condition. Conducting Performance Verification Testing Provide trend report for each HVAC system that is part of the buildings DDC system. The trend report shall include a value for each set point listed in the sequence of operation. Identify any values that do not meet the sequence of operation requirements, make repairs (re-program) and run a new trend for the system. Document each deficiency and corrective action taken. If re-testing is required, follow the procedures for the initial PVT. The Government may require re-testing of any control system components affected by the original failed test. Controller Capability and Labeling
t. u.
v. w.
3.5.5 a.
b.
c.
3.5.6
Test the following for each controller: a. Memory: Demonstrate that programmed data, parameters, and trend/ alarm history collected during normal operation is not lost during power SECTION 23 09 23.13 22 Page 45
123044
failure. b. Direct Connect Interface: Demonstrate the ability to connect directly to each type of digital controller with a portable electronic device like a notebook computer or PDA. Show that maintenance personnel interface tools perform as specified in the manufacturer's technical literature. Stand Alone Ability: Demonstrate controllers provide stable and reliable stand-alone operation using default values or other method for values normally read over the network. Building DDC system shall function to the project's specifications if connection to the EMCS server is lost. Wiring and AC Power: Demonstrate the ability to disconnect any controller safely from its power source using the AC Power Table. Demonstrate the ability to match wiring labels easily with the control drawings. Demonstrate the ability to locate a controller's location using the BACnet Communication Architecture Schematic and floor plans. Nameplates and Tags: Show the nameplates and tags are accurate and permanently attached to control panel doors, devices, sensors, and actuators. EMCS Server Operation Show points lists agree with naming conventions. Show that graphics are complete. Show the UPS operates as specified. BACnet Communications and Interoperability at the EMCS Server
c.
d.
e.
3.5.7 a. b. c. 3.5.8
Demonstrate proper interoperability of data sharing, alarm and event management, trending, scheduling, and device and network management. If available or required in this specification, use a BACnet protocol analyzer to assist with identifying devices, viewing network traffic, and verifying interoperability. These requirements must be met even if there is only one manufacturer of equipment installed. Testing includes the following: a. Data Presentation: On each BACnet Operator Workstation, demonstrate graphic display capabilities. Reading of Any Property: Demonstrate the ability to read and display any used readable object property of any device on the network. Setpoint and Parameter Modifications: Show the ability to modify all setpoints and tuning parameters in the sequence of control or listed on project schedules. Modifications are made with BACnet messages and write services initiated by an operator using workstation graphics, or by completing a field in a menu with instructional text. Peer-to-Peer Data Exchange: Show all BACnet devices are installed and configured to perform BACnet read/write services directly (without the need for operator or workstation intervention), to implement the project sequence of operation, and to share global data. Alarm and Event Management: Show that alarms/events are installed and Page 46
b.
c.
d.
e.
SECTION 23 09 23.13 22
123044
prioritized according to the BAS Owner. Demonstrate time delays and other logic is set up to avoid nuisance tripping, e.g., no status alarms during unoccupied times or high supply air during cold morning start-up. Show that operators with sufficient privilege can read and write alarm/event parameters for all standard BACnet event types. Show that operators with sufficient privilege can change routing (BACnet notification classes) for each alarm/event including the destination, priority, day of week, time of day, and the type of transition involved (TO-OFF NORMAL, TO-NORMAL, etc.). f. Schedule Lists: Show that schedules are configured for start/stop, mode change, occupant overrides, and night setback as defined in the sequence of operations. Schedule Display and Modification: Show the ability to display any schedule with start and stop times for the calendar year. Show that all calendar entries and schedules are modifiable from any connected workstation by an operator with sufficient privilege. Archival Storage of Data: Show that data archiving is handled by the operator workstation/server, and local trend archiving and display is accomplished with BACnet Trend Log objects. Modification of Trend Log Object Parameters: Show that an operator with sufficient privilege can change the logged data points, sampling rate, and trend duration. Device and Network Management: Show the following capabilities:
g.
h.
i.
j.
(1) Display of Device Status Information (2) Display of BACnet Object Information (3) Silencing Devices that are Transmitting Erroneous Data (4) Time Synchronization (5) Remote Device Reinitialization (6) Backup and Restore Device Programming and Master Database(s) (7) Configuration Management of Half-Routers, Routers and BBMDs (8) Demonstrate load shed operations if commanded by the EMCS. 3.5.9 Execution of Sequence of Operation
Demonstrate that the HVAC system operates properly through the complete sequence of operation. Use read/write property services to globally read and modify parameters over the internetwork. 3.5.10 Control Loop Stability and Accuracy
For all control loops tested, give the Government trend graphs of the control variable over time, demonstrating that the control loop responds to a 20 percent sudden change of the control variable set point without excessive overshoot and undershoot. If the process does not allow a 20 percent set point change, use the largest change possible. Show that once the new set point is reached, it is stable and maintained. Control loop SECTION 23 09 23.13 22 Page 47
123044
trend data shall be in real-time with the time between data points 30 seconds or less. 3.5.11 Performance Verification Testing Report
Upon successful completion of the PVT, submit a PVT Report to the Government and prior to the Government taking use and possession of the facility. Do not submit the report until all problems are corrected and successfully re-tested. The report shall include the annotated PVT Plan used during the PVT. Where problems were identified, explain each problem and the corrective action taken. Include a written certification that the installation and testing of the control system is complete and meets all of the contract's requirements. 3.6 TRAINING REQUIREMENTS
Provide a qualified instructor (or instructors) with two years minimum field experience with the installation and programming of similar BACnet DDC systems. Orient training to the specific systems installed. Coordinate training times with the Contracting Officer and BAS Owner after receiving approval of the training course documentation. Training shall take place at the job site and/or a nearby Government-furnished location. A training day shall occur during normal working hours, last no longer than 8 hours and include a one-hour break for lunch and two additional 15-minute breaks. The project's approved Controls System Operators Manual shall be used as the training text. The Contractor shall ensure the manuals are submitted, approved, and available to hand out to the trainees before the start of training. 3.6.1 Training Documentation
Submit training documentation for review 30 days minimum before training. Documentation shall include an agenda for each training day, objectives, a synopses of each lesson, and the instructor's background and qualifications. The training documentation can be submitted at the same time as the project's Controls System Operators Manual. 3.6.2 Phase I Training - Fundamentals
The Phase I training session shall last one day and be conducted in a classroom environment with complete audio-visual aids provided by the contractor. Provide each trainee a printed 8.5 by 11 inch hard-copy of all visual aids used. Upon completion of the Phase I Training, each trainee should fully understand the project's DDC system fundamentals. The training session shall include the following: a. Review of O&M Manual 1. 2. 3. 4. 5. 6. 7. 8. b. Network Network Drawing Equipment Flow Diagram Sequence of Operation Wiring Valve Schedule Damper Schedule Bill of Material
SECTION 23 09 23.13 22
Page 48
123044
1. Communication Equipment 2. Configuration Setup of Program 3. Backup Procedures c. Mechanical Equipment 1. 2. 3. 4. 5. Flow Diagram Wiring & Terminations Hardware Interlocks Sequence of Operation Program Decisions and Illustrations of How Program Meets the Sequence of Operation 6. Global Programming Affecting Each Piece of Equipment d. Building Data Base 1. 2. 3. 4. 5. Alarm Management Trend Management Building Global Interlocks System Load Shedding & Demand Limiting Utility Data (Water, Steam, Solar)
e. System Tools 1. 2. 3. 4. 3.6.3 Network Equipment Supervisory Controllers Equipment Controllers Archives
Phase II Training - Operation
Provide Phase II Training shortly after completing Phase I Training. The Phase II training session shall last one day and be conducted at the DDC system workstation, at a notebook computer connected to the DDC system in the field, and at other site locations as necessary. Upon completion of the Phase II Training, each trainee should fully understand the project's DDC system operation. The training session shall include the following: a. A walk-through tour of the mechanical system and the installed DDC components (controllers, valves, dampers, surge protection, switches, thermostats, sensors, etc.) Adding and removing network devices -- End of Section --
b.
SECTION 23 09 23.13 22
Page 49
123044
SECTION 23 11 25 FACILITY GAS PIPING 11/08 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. AMERICAN GAS ASSOCIATION (AGA) AGA ANSI B109.3 AGA XR0603 (2000) Rotary-Type Gas Displacement Meters (2006; 8th Ed) AGA Plastic Pipe Manual for Gas Service
AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) ANSI Z21.15/CSA 9.1 (2009) Manually Operated Gas Valves for Appliances, Appliance Connector Valves and Hose End Valves (2007; Addenda A 2010) Gas Appliance Pressure Regulators (2005; Addenda A 2010) Automatic Valves for Gas Appliances (2003; Addenda A 2005; R 2008) Line Pressure Regulators
ANSI Z21.18/CSA 6.3
ANSI Z21.21/CSA 6.5
ANSI Z21.80/CSA 6.22
AMERICAN PETROLEUM INSTITUTE (API) API 570 (2009, 3rd Ed) Piping Inspection Code: In-Service Inspection, Rating, Repair, and Alteration of Piping Systems (2002; R 2007; 7th Ed) Safe Welding, Cutting, and Hot Work Practices in Refineries, Gasoline Plants, and Petrochemical Plants (2008; Errata 2008; Errata 2008; Errata 2009; Addendum 2009; Errata 2010) Specification for Pipeline Valves (2009) Valve Inspecting and Testing (2010) Testing of Valves: Fire Test for Soft-Seated Quarter-Turn Valves
API RP 2009
API Spec 6D
API Std 598 API Std 607
SECTION 23 11 25
Page 1
123044
ASME INTERNATIONAL (ASME) ASME A13.1 (2007) Scheme for the Identification of Piping Systems (1983; R 2006) Pipe Threads, General Purpose (Inch) (2009) Forged Fittings, Socket-Welding and Threaded (2011) Nonmetallic Flat Gaskets for Pipe Flanges (200610) Malleable Iron Threaded Fittings, Classes 150 and 300 (2002; R 2007) Manually Operated Metallic Gas Valves for Use in Gas Piping Systems Up to 125 psi, Sizes NPS 1/2 - NPS 2 (2009) Standard for Malleable Iron Threaded Pipe Unions; Classes 150, 250, and 300 (2009) Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24 Metric/Inch Standard (2007) Standard for Factory-Made Wrought Steel Buttwelding Fittings (20082011) Building Services Piping (2005) Pressure Gauges and Gauge Attachments (2010) BPVC Section IX-Welding and Brazing Qualifications (2007; Addenda 2008; Addenda 2009) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1
ASME B1.20.1
ASME B16.11
ASME B16.21
ASME B16.3
ASME B16.33
ASME B16.39
ASME B16.5
ASME B16.9
ASME B31.9 ASME B40.100
ASME BPVC SEC IX
ASME BPVC SEC VIII D1
ASTM INTERNATIONAL (ASTM) ASTM A53/A53M (2010) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless
CSA STANDARDS (CSA) CGA 3.11-M88 (1988; R 2009) Lever Operated Pressure Lubricated Plug Type Gas Shut-Off Valves
MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS) MSS SP-25 (2008) Standard Marking System for Valves, Fittings, Flanges and Unions SECTION 23 11 25 Page 2
123044
MSS SP-58
(2009) Pipe Hangers and Supports Materials, Design and Manufacture, Selection, Application, and Installation (2003) Pipe Hangers and Supports Selection and Application (ANSI Approved American National Standard)
MSS SP-69
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA 54 NFPA 70 (2009; TIA 10-3) National Fuel Gas Code (2011) National Electrical Code(2008) National Electrical Code UNDERWRITERS LABORATORIES (UL) UL Gas&Oil Dir (2009) Flammable and Combustible Liquids and Gases Equipment Directory
1.2
SYSTEM DESCRIPTION
The gas piping system includes natural gas piping and appurtenances from point of connection with supply system, as indicated, to gas operated equipment within the facility. Submit operation and maintenance data in accordance with Section 01 78 24.05 2023 FACILITY OPERATION AND MAINTENANCE DATASUPPORT INFORMATION, in three separate packages. Section 23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS applies to this section, with additions and modifications specified herein. [Provide cathodically protected insulating joints connecting aboveground piping from the meter to the building, with [lightning arrestors] [zinc grounding cells] conforming to API RP 2003, installed where indicated.] 1.2.1 Gas Facility System and Equipment Operation
Include shop drawings showing piping layout, locations of system valves, gas line markers[ and cathodic protection system]; step-by-step procedures for system start up, operation and shutdown (index system components and equipment to the system drawings); isolation procedures including valve operation to shutdown or isolate each section of the system (index valves to the system maps and provide separate procedures for normal operation and emergency shutdown if required to be different). Submit Data package No. 4. 1.2.2 Gas Facility System Maintenance
Include maintenance procedures and frequency for system and equipment; identification of pipe materials and manufacturer by locations, pipe repair procedures, and jointing procedures at transitions to other piping material or material from a different manufacturer. Submit Data Package No.4. 1.2.3 Gas Facility Equipment Maintenance
Include identification of valves, shut-offs, disconnects, and other equipment by materials, manufacturer, vendor identification and location; maintenance procedures and recommended tool kits for valves and equipment; recommended repair methods (i.e., field repair, factory repair, or replacement) for each valve and piece of equipment; and preventive maintenance procedures, possible failure modes and troubleshooting guide. SECTION 23 11 25 Page 3
123044
Submit Data Package No. 3. 1.3 SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for [Contractor Quality Control approval.] [information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] Submit the following in accordance with Section 01 33 00.05 20 CONSTRUCTION SUBMITTAL PROCEDURES: SD-02 Shop Drawings Gas Piping System[; G][; G, [_____]] SD-03 Product Data Pipe and Fittings[; G][; G, [_____]] Gas equipment connectors[; G][; G, [_____]] Gas Piping System[; G][; G, [_____]] Pipe Coating Materials and application procedures[; G][; G, [_____] ] Pressure regulators[; G][; G, [_____]] Risers[; G][; G, [_____]] Transition fittings[; G][; G, [_____]] Valves[; G][; G, [_____]] Valve box[; G][; G, [_____]] Warning and identification tape[; G][; G, [_____]] SD-06 Test Reports Testing[; G][; G, [_____]] Pressure Tests[; G][; G, [_____]] Test With Gas[; G][; G, [_____]] SD-07 Certificates Welders procedures and qualifications[; G][; G, [_____]] assigned number, letter, or symbol[; G][; G, [_____]] SD-08 Manufacturer's Instructions PE pipe and fittings[; G][; G, [_____]] pipe coating materials and application procedures[; G][; G, [_____] ] SD-10 Operation and Maintenance Data Gas facility system and equipment operation[; G][; G, [_____]] Gas facility system maintenance[; G][; G, [_____]] Gas facility equipment maintenance[; G][; G, [_____]] Data packages, as specified. 1.4 QUALITY ASSURANCE
Submit manufacturer's descriptive data and installation instructions for SECTION 23 11 25 Page 4
123044
approval for compression-type mechanical joints used in joining dissimilar materials and for insulating joints. Mark all valves, flanges and fittings in accordance with MSS SP-25. 1.4.1 Welding Qualifications a. Weld piping in accordance with qualified procedures using performance qualified welders and welding operators in accordance with API RP 2009, ASME BPVC SEC IX, and ASME B31.9. Welding procedures qualified by others, and welders and welding operators qualified by another employer may be accepted as permitted by ASME B31.9. Notify the Contracting Officer at least 24 hours in advance of tests, and perform at the work site if practicable. b. Submit a certified copy of welders procedures and qualifications metal and PE in conformance with ASME B31.9 for each welder and welding operator. Submit the assigned number, letter, or symbol that will be used in identifying the work of each welder to the Contracting Officer. [ Weld all structural members in accordance with Section 05 05 23 WELDING, STRUCTURAL, and in conformance with AWS A5.8/A5.8M, and AWS WHB-2.9.] 1.4.2 Jointing Thermoplastic and Fiberglass Piping
Perform all jointing of piping using qualified joiners and qualified procedures in accordance with AGA XR0603. Furnish the Contracting Officer with a copy of qualified procedures and list of and identification symbols of qualified joiners. Submit manufacturer's installation instructions and manufacturer's visual joint appearance chart, including all PE pipe and fittings. 1.4.3 Shop Drawings for complete Gas Piping System, within [30] [_____] days of showing location, size and all branches of pipeline; required shutoff valves; and instructions necessary for the gas equipment connectors and supports.
Submit drawings contract award, location of all installation of 1.5
DELIVERY, STORAGE, AND HANDLING
Handle, transport, and store plastic pipe and fittings carefully. Plug or cap pipe and fittings ends during transportation or storage to minimize dirt and moisture entry. Do not subject piping to abrasion or concentrated external loads. Discard PE pipe sections and fittings that have been damaged. PART 2 2.1 PRODUCTS MATERIALS AND EQUIPMENT
Provide materials and equipment which are the standard products of a manufacturer regularly engaged in the manufacture of the products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Asbestos or products containing asbestos are not allowed. Submit catalog data and installation instructions for pipe, valves, all related system components, pipe coating materials and application procedures. Conform to NFPA 54 and with requirements specified herein. Provide supply piping to appliances or equipment at least as large as the inlets thereof. SECTION 23 11 25 Page 5
123044
2.2 [2.2.1
GAS PIPING SYSTEM AND FITTINGS Steel Pipe, Joints, and Fittings a. Pipe: Black carbon steel in accordance with ASTM A53/A53M, Schedule [40] [80], threaded ends for sizes 2 inches and smaller; otherwise, plain end beveled for butt welding. b. c. Threaded Fittings: ASME B16.3, black malleable iron. ASME B16.11, forged steel. ASME B16.9, with backing rings of
Socket-Welding Fittings:
d. Butt-Welding Fittings: compatible material. e. Unions:
ASME B16.39, black malleable iron.
f. Flanges and Flanged Fittings: ASME B16.5 steel flanges or convoluted steel flanges conforming to ASME BPVC SEC VIII D1, with flange faces having integral grooves of rectangular cross sections which afford containment for self-energizing gasket material. ][2.2.2 Aluminum Alloy Pipe and Tubing, Joints, and Fittings
Provide aluminum alloy pipe conforming to ASTM B 241/B 241M, except that alloy 5456 is not allowed. Mark the ends of each length of pipe indicating it conforms to NFPA 54 . Thread, flange, braze, or weld pipe joints. Provide aluminum alloy tubing conforming to ASTM B 210, Type A or B, or ASTM B 241/B 241M, Type A or equivalent, with joints made up with gas tubing fittings recommended by the tubing manufacturer. ][2.2.3 Copper Tubing, Joints and Fittings
Provide copper tubing conforming to ASTM B 88, Type K or L, or ASTM B 280, with tubing joints made up with tubing fittings recommended by the tubing manufacturer. Provide copper and copper alloy press fittings, with sealing elements of Hydrogenated Nitrile Butadiene Rubber (HNBR), factory installed, or an alternative supplied by the fitting manufacturer. ][2.2.4 Steel Tubing, Joints and Fittings
Provide steel tubing conforming to ASTM 01.01, and ASTM A513, with tubing joints made up with gas tubing fittings recommended by the tubing manufacturer. ][2.2.2 [Enter Appropriate Subpart Title Here]
Provide thermoplastic pipe, tubing,casing and joints and fittings conforming to ASTM D 2513 and API Spec 5CT. ][2.2.6 Fiberglass Pipe, Joints, and Fittings
Provide fiberglass piping systems conforming to ASTM D 2517 and API Spec 15LR. ][2.2.3 Sealants for Steel Pipe Threaded Joints
Provide joint sealing compound as listed in UL Gas&Oil Dir, Class 20 or SECTION 23 11 25 Page 6
123044
less. ]2.2.4
For taping, use tetrafluoroethylene tape conforming to UL Gas&Oil Dir. Warning and Identification
Provide pipe flow markings, warning and identification tape, and metal tags as required. 2.2.5 Flange Gaskets
Provide gaskets of nonasbestos compressed material in accordance with ASME B16.21, 1/16 inch thickness, full face or self-centering flat ring type, containing aramid fibers bonded with styrene butadiene rubber (SBR) or nitrile butadiene rubber (NBR) suitable for a maximum 600 degree F service, to be used for hydrocarbon service. 2.2.6 Pipe Threads
Provide pipe threads conforming to ASME B1.20.1. 2.2.7 Escutcheons
Provide chromium-plated steel or chromium-plated brass escutcheons, either one piece or split pattern, held in place by internal spring tension or set screw. 2.2.8 Gas Transition Fittings [a. Provide steel to plastic (PE) designed for steel-to-plastic with tapping tee or sleeve conforming to AGA XR0603 requirements for transitions fittings.. Coat or wrap exposed steel pipe with heavy plastic coating.] [b. Plastic to Plastic: [Manufacturer's standard bolt-on (PVC to PE) plastic tapping saddle tee, UL listed for gas service, rated for 100 psig, and O-ring seals.] [Manufacturer's standard slip-on PE mechanical coupling, molded, with stainless-steel ring support conforming to ASTM A666, O-ring seals, and rated for 150 psig gas service.] [Manufacturer's standard fused tapping (PE-to-PE) tee assembly with shut-off feature.]] [cb.[ Provide lever operated pressure lubricated plug type gas shut-off valve conforming to CGA 3.11-M88.][ Provide lever operated non-lubricated gas shut-off valves conforming to CGA 3.16-M88][ Provide manually operated shut-off valve conforming to CGA 9.2-M88]] 2.2.9 2.2.9.1 Insulating Pipe Joints Insulating Joint Material
Provide insulating joint material between flanged or threaded metallic pipe systems where shown to control galvanic or electrical action. 2.2.9.2 Threaded Pipe Joints
Provide threaded pipe joints of steel body nut type dielectric unions with insulating gaskets.
SECTION 23 11 25
Page 7
123044
2.2.9.3
Flanged Pipe Joints
Provide joints for flanged pipe consisting of full face sandwich-type flange insulating gasket of the dielectric type, insulating sleeves for flange bolts, and insulating washers for flange nuts. [Provide lap joint flange pipe ends conforming to ASTM F 2015.] 2.2.10 [Enter Appropriate Subpart Title Here]2.2.14 Flexible Connectors
a. Provide flexible connectors for connecting gas utilization equipment to building gas piping conforming to ANSI Z21.24/CSA 6.10 or ANSI Z21.41/CSA 6.9 for quick disconnect devices, and flexible connectors for movable food service equipment conforming to ANSI Z21.69/CSA 6.16.[ Provide combination gas controls for gas appliances conforming to ANSI Z21.78/CSA 6.20.] b. Do not install the flexible connector through the appliance cabinet face. Provide rigid metallic pipe and fittings to extend the final connection beyond the cabinet, except when appliance is provided with an external connection point. 2.3 VALVES
Provide [lockable ]shutoff or service isolation valves [as indicated in the drawings ]conforming to the following: 2.3.1 Valves 2 Inches and Smaller
Provide valves 2 inches and smaller conforming to ASME B16.33 of materials and manufacture compatible with system materials used.[ Provide manually operated household cooking gas appliance valves conforming to ANSI Z21.1 and ANSI Z21.15/CSA 9.1.] [2.3.2 Valves 2-1/2 Inches and Larger
Provide valves 2-1/2 inches and larger of carbon steel conforming to API Spec 6D, Class 150. ]2.4 RISERS
Provide manufacturer's standard riser, transition from plastic to steel pipe with 7 to 12 mil thick epoxy coating. Use swaged gas-tight construction with O-ring seals, metal insert, and protective sleeve. Provide [remote bolt-on or bracket] [or] [wall-mounted] riser supports [as indicated on the drawings]. 2.5 PIPE HANGERS AND SUPPORTS
Provide pipe hangers and supports conforming to MSS SP-58 and MSS SP-69. [2.6 [METERING, ]REGULATORS AND SHUTOFF VALVES
[Provide [diaphragm-type meter conforming to AGA ANSI B109.1] [rotary-type displacement meter conforming to AGA ANSI B109.3] as required by local gas utility supplier,[ including valve box] conforming to NFPA 54.] Provide pressure gauges and attachments conforming to ASME B40.100. Provide regulators conforming to [ANSI Z21.18/CSA 6.3 for appliances] [ ANSI Z21.78/CSA 6.20 for combination gas controls for gas appliances] [, and ANSI Z21.80/CSA 6.22 for line pressure regulators]. Provide shutoff SECTION 23 11 25 Page 8
123044
valves conforming to [ANSI Z21.15/CSA 9.1 for manually controlled gas shutoff valves] [and] [ANSI Z21.21/CSA 6.5 for automatic shutoff valves for gas appliances]. ][2.7 SEISMIC PROVISIONS
Provide earthquake automatic gas shutoff valve conforming to ASCE 25-06, SMACNA 1650, and UL listed or AGA listed or International Association of Plumbing and Mechanical Officials (IAPMO) listed. The valve may be either pendulum or ball construction with [remote [, pneumatic] [electronic] [or] [electric]] actuator. ]PART 3 3.1 EXECUTION
EXAMINATION
After becoming familiar with all details of the work, verify all dimensions in the field, and advise the Contracting Officer of any discrepancy or areas of conflict before performing the work. 3.2 EXCAVATION AND BACKFILLING
Provide required excavation, backfilling, and compaction as specified in Section 31 00 00 EARTHWORK31 23 00.00 20 EXCAVATION AND FILL included in the DP-1 Site Design Package. 3.3 GAS PIPING SYSTEM system from the point of delivery, defined as the set assembly] [service regulator] [shutoff valve], as 33 51 15 NATURAL-GAS / LIQUID PETROLEUM GAS connections to each gas utilization device.
Provide a gas piping outlet of the [meter specified in Section DISTRIBUTION, to the 3.3.1
Protection and Cleaning of Materials and Components
Protect equipment, pipe, and tube openings by closing with caps or plugs during installation. At the completion of all work, thoroughly clean the entire system. 3.3.2 Workmanship and Defects
Piping, tubing and fittings shall be clear and free of cutting burrs and defects in structure or threading and shall be thoroughly brushed and chip-and scale-blown. Repair of defects in piping, tubing or fittings is not allowed; replace defective items when found. 3.4 3.4.1 PROTECTIVE COVERING Underground Metallic Pipe
Protect buried metallic piping from corrosion with protective coatings as specified in Section 33 51 15 NATURAL-GAS / LIQUID PETROLEUM GAS DISTRIBUTION. When dissimilar metals are joined underground, use gastight insulating fittings.
SECTION 23 11 25
Page 9
123044
3.4.2 3.4.2.1
Aboveground Metallic Piping Systems Ferrous Surfaces
Touch up shop primed surfaces with ferrous metal primer. Solvent clean surfaces that have not been shop primed . Mechanically clean surfaces that contain loose rust, loose mill scale and other foreign substances [by power wire brushing] [or] [commercial sand blasted conforming to SSPC SP 6/NACE No.3] and prime with [ferrous metal primer] [or] [vinyl type wash coat]. Finish primed surfaces with two coats of exterior [oil paint] [ or] [vinyl paint]. 3.4.2.2 Nonferrous Surfaces
Except for aluminum alloy pipe, do not paint nonferrous surfaces. Paint surfaces of aluminum alloy pipe and fittings to protect against external corrosion where they contact masonry, plaster, insulation, or are subject to repeated wettings by such liquids as water, detergents or sewage. Solvent-clean the surfaces and treat with vinyl type wash coat. Apply a first coat of aluminum paint and a second coat of alkyd gloss enamel or silicone alkyd copolymer enamel. 3.5 INSTALLATION
Install the gas system in conformance with the manufacturer's recommendations and applicable provisions of NFPA 54, AGA XR0603, and as indicated. Perform all pipe cutting without damage to the pipe, with an approved type of mechanical cutter, unless otherwise authorized. Use wheel cutters where practicable. On steel pipe 6 inches and larger, an approved gas cutting and beveling machine may be used. Cut thermoplastic and fiberglass pipe in accordance with AGA XR0603. 3.5.1 Metallic Piping Installation
Bury underground piping a minimum of 18 inches below grade. Make changes in direction of piping with fittings only; mitering or notching pipe to form elbows and tees or other similar type construction is not permitted. Branch connection may be made with either tees or forged branch outlet fittings. Provide branch outlet fittings which are forged, flared for improvement of flow where attached to the run, and reinforced against external strains. Do not use aluminum alloy pipe in exterior locations or underground. 3.5.2 Metallic Tubing Installation
Install metallic tubing using gas tubing fittings approved by the tubing manufacturer. Make branch connections with tees. Prepare all tubing ends with tools designed for that purpose. Do not use aluminum alloy tubing in exterior locations or underground. 3.5.2 Thermoplastic and Fiberglass Piping, Tubing, and Fittings
Installation of thermoplastic and fiberglass piping, tubing, and fittings is permitted only outside and underground. Bury piping a minimum of 18 inches below grade. Install the piping to avoid excessive stresses due to thermal contraction, and use only where indicated.
SECTION 23 11 25
Page 10
123044
3.5.3
Connections Between Metallic and Plastic Piping
Connections between metallic and plastic piping are only allowed outside, underground, and with approved transition fittings. 3.5.5 Piping Buried Under Buildings
Run underground piping installed beneath buildings in a steel pipe casing protected from corrosion with protective coatings as specified in Section 23 11 25 FACILITY GAS PIPING. Extend casing at least 4 inches outside the building, and provide the pipe with spacers and end bushings to seal at both ends to prevent the entrance of water and/or the escape of gas. Extend a vent line from the annular space above grade outside to a point where gas will not be a hazard, and terminate in a rain/insect-resistant fitting. 3.5.4 Concealed Piping in Buildings
Do not use combinations of fittings ( unions, tubing fittings, running threads, right- and left-hand couplings, bushings, and swing joints) to conceal piping within buildings. 3.5.4.1 Piping in Partitions
Locate concealed piping in hollow, rather than solid, partitions. Protect tubing passing through walls or partitions against physical damage both during and after construction, and provide appropriate safety markings and labels.. 3.5.6.2 Piping in Floors
Lay piping in solid floors [except where embedment in concrete is indicated] in channels suitably covered to permit access to the piping with minimum damage to the building. [Surround piping embedded in concrete by a minimum of 1-1/2 inches of concrete and do not allow physical contact with other metallic items such as reinforcing rods or electrically neutral conductors. Do not embed piping in concrete slabs containing quickset additives or cinder aggregate.] 3.5.5 Aboveground Piping
Run aboveground piping as straight as practicable along the alignment and elevation indicated, with a minimum of joints, and separately supported from other piping system and equipment. Install exposed horizontal piping no farther than 6 inches from nearest parallel wall and at an elevation which prevents standing, sitting, or placement of objects on the piping. 3.5.6 Final Gas Connections
Unless otherwise specified, make final connections with rigid metallic pipe and fittings. [Make final connections to kitchen ranges using flexible connectors not less than 40 inch long[, to afford access to coupling] [and][ to permit movement of equipment for cleaning].][ Flexible connectors may be used for final connections to residential dryers.] [ Flexible connectors may be used for final connections to gas utilization equipment.] [In addition to cautions listed in instructions required by ANSI standards for flexible connectors, insure that flexible connectors do not pass through equipment cabinet.] Provide accessible gas shutoff valve and coupling for each gas equipment item. SECTION 23 11 25 Page 11
123044
3.5.9
Seismic Requirements brace piping and attached valves to resist seismic loads in with ASCE 25-06[ and ][as specified in UFC 3-310-04, and 48 00 SEISMIC PROTECTION FOR MISCELLANEOUS EQUIPMENT and 10 SEISMIC PROTECTION FOR MECHANICAL EQUIPMENT][as shown on the
Support and conformance Sections 13 13 48 00.00 drawings]. 3.6
PIPE JOINTS
Design and install pipe joints to effectively sustain the longitudinal pull-out forces caused by contraction of the piping or superimposed loads. 3.6.1 Threaded Metallic Joints
Provide threaded joints in metallic pipe with tapered threads evenly cut and made with UL approved graphite joint sealing compound for gas service or tetrafluoroethylene tape applied to the male threads only. Threaded joints up to 1-1/2 inches in diameter may be made with approved tetrafluoroethylene tape. Threaded joints up to 2 inches in diameter may be made with approved joint sealing compound. After cutting and before threading, ream pipe and remove all burrs. Caulking of threaded joints to stop or prevent leaks is not permitted. 3.6.2 Welded Metallic Joints
Conform beveling, alignment, heat treatment, and inspection of welds to NFPA 54. Remove weld defects and make repairs to the weld, or remove the weld joints entirely and reweld. After filler metal has been removed from its original package, protect and store so that its characteristics or welding properties are not affected adversely. Do not use electrodes that have been wetted or have lost any of their coating. 3.6.3 Thermoplastic and Fiberglass Joints a. Thermoplastic and Fiberglass: Conform jointing procedures to AGA XR0603. Do not make joints with solvent cement or heat of fusion between different kinds of plastics. b. PE Fusion Welding Inspection: Visually inspect butt joints by comparing with, manufacturer's visual joint appearance chart. Inspect fusion joints for proper fused connection. Replace defective joints by cutting out defective joints or replacing fittings. Inspect, in conformance with API 570, 100 percent of all joints and re-inspect all corrections. Arrange with the pipe manufacturer's representative in the presence of the Contracting Officer to make first time inspection. 3.6.4 Flared Metallic Tubing Joints
Make flared joints in metallic tubing with special tools recommended by the tubing manufacturer. Use flared joints only in systems constructed from nonferrous pipe and tubing, when experience or tests have demonstrated that the joint is suitable for the conditions, and when adequate provisions are made in the design to prevent separation of the joints. Do not use metallic ball sleeve compression-type tubing fittings for tubing joints.
SECTION 23 11 25
Page 12
123044
3.6.5
Solder or Brazed Joints
Make all joints in metallic tubing and fittings with materials and procedures recommended by the tubing supplier. Braze joints with material having a melting point above 1000 degrees F, containing no phosphorous. 3.6.6 Joining Thermoplastic or Fiberglass to Metallic Piping or Tubing
When compression type mechanical joints are used, provide gasket material in the fittings compatible with the plastic piping and with the gas in the system. Use an internal tubular rigid stiffener in conjunction with the fitting, flush with end of the pipe or tubing, extending at least to the outside end of the compression fitting when installed. Remove all rough or sharp edges from stiffener. Do not force fit stiffener in the plastic. Split tubular stiffeners are not allowed. 3.6.7 Press Connections
Make press connections in accordance with manufacturer's installation instructions using tools approved by the manufacturer. Fully insert the tubing into the fitting and then mark at the shoulder of the fitting. Check the fitting alignment against the mark on the tubing to assure the tubing is fully inserted before the joint is pressed. 3.7 PIPE SLEEVES
Provide pipes passing through concrete or masonry walls or concrete floors or roofs with pipe sleeves fitted into place at the time of construction. Do not install sleeves in structural members except where indicated or approved. Make all rectangular and square openings as detailed. Extend each sleeve through its respective wall, floor or roof, and cut flush with each surface, except in mechanical room floors not located on grade where clamping flanges or riser pipe clamps are used. Extend sleeves in mechanical room floors above grade at least 4 inches above finish floor. Unless otherwise indicated, use sleeves large enough to provide a minimum clearance of 1/4 inch all around the pipe. Provide steel pipe for sleeves in bearing walls, waterproofing membrane floors, and wet areas . Provide sleeves in nonbearing walls, floors, or ceilings of steel pipe, galvanized sheet metal with lock-type longitudinal seam, or moisture-resistant fiber or plastic. For penetrations of fire walls, fire partitions and floors which are not on grade, seal the annular space between the pipe and sleeve with fire-stopping material and sealant that meet the requirement of Section 07 84 00 WIRETAPPINGFIRE STOPPING. 3.8 PIPES PENETRATING WATERPROOFING MEMBRANES
Install pipes penetrating waterproofing membranes as specified in Section 22 00 00 PLUMBING, GENERAL PURPOSE. 3.9 FIRE SEAL
Fire seal all penetrations of fire rated partitions, walls and floors in accordance with Section 07 84 00 FIRESTOPPING. 3.10 ESCUTCHEONS
Provide escutcheons for all finished surfaces where gas piping passes through floors, walls, or ceilings except in boiler, utility, or equipment rooms. SECTION 23 11 25 Page 13
123044
3.11
SPECIAL REQUIREMENTS
Provide drips, grading of the lines, freeze protection, and branch outlet locations as shown and conforming to the requirements of NFPA 54. 3.12 BUILDING STRUCTURE
Do not weaken any building structure by the installation of any gas piping. Do not cut or notch beams, joists or columns. Attach piping supports to metal decking. Do not attach supports to the underside of concrete filled floors or concrete roof decks unless approved by the Contracting Officer. 3.13 PIPING SYSTEM SUPPORTS
Support gas piping systems in buildings with pipe hooks, metal pipe straps, bands or hangers suitable for the size of piping or tubing. Do not support any gas piping system by other piping. Conform spacing of supports in gas piping and tubing installations to the requirements of NFPA 54. Conform the selection and application of supports in gas piping and tubing installations to the requirements of MSS SP-69. In the support of multiple pipe runs on a common base member, use a clip or clamp where each pipe crosses the base support member. Spacing of the base support members is not to exceed the hanger and support spacing required for any of the individual pipes in the multiple pipe run. Rigidly connect the clips or clamps to the common base member. Provide a clearance of 1/8 inch between the pipe and clip or clamp for all piping which may be subjected to thermal expansion. 3.14 ELECTRICAL BONDING AND GROUNDING
Provide a gas piping system within the building which is electrically continuous and bonded to a grounding electrode as required by NFPA 70. 3.15 SHUTOFF VALVE
Install the main gas shutoff valve controlling the gas piping system to be easily accessible for operation, as indicated, protected from physical damage, and marked with a metal tag to clearly identify the piping system controlled. [3.16 CATHODIC PROTECTION
Provide cathodic protection for underground ferrous gas piping as specified in [Section 26 42 13.00 20 CATHODIC PROTECTION BY GALVANIC ANODES] [Section 26 42 19.00 20 CATHODIC PROTECTION BY IMPRESSED CURRENT]. ]3.16 TESTING
Submit test reports in booklet form tabulating test and measurements performed; dated after award of this contract, and stating the Contractor's name and address, the project name and location, and a list of the specific requirements which are being certified. Test entire gas piping system to ensure that it is gastight prior to putting into service. Prior to testing, blow out the system, clean, and clear all foreign material. Test each joint with an approved gas detector, soap and water, or an equivalent nonflammable solution. Inspect and test each valve in conformance with API Std 598 and API Std 607. Complete testing before any work is covered, SECTION 23 11 25 Page 14
123044
enclosed, or concealed, and perform with due regard for the safety of employees and the public during the test. Install bulkheads, anchorage and bracing suitably designed to resist test pressures if necessary, and as directed and or approved by the Contracting Officer. Do not use oxygen as a testing medium. 3.16.1 Pressure Tests
Submit test reports in booklet form tabulating test and measurements performed; dated after award of this contract, and stating the Contractor's name and address, the project name and location, and a list of the specific requirements which are being certified. Before appliances are connected, test by filling the piping systems with air or an inert gas to withstand a minimum pressure of 3 pounds gauge for a period of not less than 10 minutes as specified in NFPA 54 without showing any drop in pressure. Do not use Oxygen for test. Measure pressure with a mercury manometer, slope gauge, or an equivalent device calibrated to be read in increments of not greater than 0.1 pound. Isolate the source of pressure before the pressure tests are made. 3.16.2 Test With Gas
Before turning on gas under pressure into any piping, close all openings from which gas can escape. Immediately after turning on the gas, check the piping system for leakage by using a laboratory-certified gas meter, an appliance orifice, a manometer, or equivalent device. Conform all testing to the requirements of NFPA 54. If leakage is recorded, shut off the gas supply, repair the leak , and repeat the tests until all leaks have been stopped. 3.16.3 Purging
After testing is completed, and before connecting any appliances, fully purge all gas piping. Do not purge piping into the combustion chamber of an appliance. Do not purge the open end of piping systems into confined spaces or areas where there are ignition sources unless the safety precautions recommended in NFPA 54 are followed. 3.16.4 Labor, Materials and Equipment
Furnish all labor, materials and equipment necessary for conducting the testing and purging. 3.17 PIPE COLOR CODE MARKING
Provide color code marking of piping as specified in Section 09 90 00 PAINTS AND COATINGS, conforming to ASME A13.1. -- End of Section --
SECTION 23 11 25
Page 15
123044
SECTION 23 21 13.00 20 LOW TEMPERATURE WATER (LTW) HEATING SYSTEM 04/06 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. ACOUSTICAL SOCIETY OF AMERICA (ASA) ASA S1.4 (1983; Amendment 1985; R 2006) Specification for Sound Level Meters (ASA 47) AMERICAN SOCIETY OF SANITARY ENGINEERING (ASSE) ASSE 1003 (2009) Performance Requirements for Water Pressure Reducing Valves for Domestic Water Distribution Systems - (ANSI approved 2010) (2009) Performance Requirements for Temperature Actuated Mixing Valves for Hot Water Distribution Systems - (ANSI approved 2010)
ASSE 1017
AMERICAN WELDING SOCIETY (AWS) AWS Z49.1 (2005) Safety in Welding and Cutting and Allied Processes
ASME INTERNATIONAL (ASME) ASME B1.1 (2003; R 2008) Unified Inch Screw Threads (UN and UNR Thread Form) (1983; R 2006) Pipe Threads, General Purpose (Inch) (2010) Gray Iron Threaded Fittings; Classes 25, 125 and 250 (2009) Forged Fittings, Socket-Welding and Threaded (2001; R 2005) Cast Copper Alloy Solder Joint Pressure Fittings (2011) Nonmetallic Flat Gaskets for Pipe Flanges (2001; R 2010) Standard for Wrought Copper and Copper Alloy Solder Joint Pressure SECTION 23 21 13.00 20 Page 1
ASME B1.20.1
ASME B16.1
ASME B16.11
ASME B16.18
ASME B16.21
ASME B16.22
123044
Fittings ASME B16.24 (2006) Cast Copper Alloy Pipe Flanges and Flanged Fittings: Classes 150, 300, 600, 900, 1500, and 2500 (2010) Malleable Iron Threaded Fittings, Classes 150 and 300 (2009; Supp 2010) Valves - Flanged, Threaded and Welding End (2009) Orifice Flanges (2009) Standard for Malleable Iron Threaded Pipe Unions; Classes 150, 250, and 300 (2009) Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24 Metric/Inch Standard (2007) Standard for Factory-Made Wrought Steel Buttwelding Fittings (2010) Standard for Square and Hex Nuts (2011) Building Services Piping (2005) Pressure Gauges and Gauge Attachments (2007; Addenda 2008; Addenda 2009) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1
ASME B16.3
ASME B16.34
ASME B16.5
ASME B16.9
ASME B18.2.2 ASME B31.9 ASME B40.100
ASME BPVC SEC VIII D1
ASTM INTERNATIONAL (ASTM) ASTM A194/A194M (2010a) Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both (2010) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength (2010) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless (2008) Standard Specification for Solder Metal (2009) Standard Specification for Seamless Copper Water Tube (2006) Standard Specification for Poly(Vinyl Chloride) (PVC), Plastic Pipe, Schedules 40, 80, and 120 SECTION 23 21 13.00 20 Page 2
ASTM A307
ASTM A53/A53M
ASTM B32
ASTM B88
ASTM D 1785
123044
COPPER DEVELOPMENT ASSOCIATION (CDA) CDA A4015 (1994; R 1995) Copper Tube Handbook
MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS) MSS SP-110 (2010) Ball Valves Threaded, Socket-Welding, Solder Joint, Grooved and Flared Ends (2009) Pipe Hangers and Supports Materials, Design and Manufacture, Selection, Application, and Installation (2002a) Butterfly Valves (2003) Pipe Hangers and Supports Selection and Application (ANSI Approved American National Standard) (2006) Gray Iron Gate Valves, Flanged and Threaded Ends (2010) Ball Valves with Flanged or Butt-Welding Ends for General Service (2008) Bronze Gate, Globe, Angle and Check Valves (2002) Gray Iron Globe & Angle Valves Flanged and Threaded Ends
MSS SP-58
MSS SP-67 MSS SP-69
MSS SP-70
MSS SP-72
MSS SP-80
MSS SP-85
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload Relays Rated 600 V (1993; R 2006) Enclosures (2009) Motors and Generators
NEMA ICS 6 NEMA MG 1
U.S. DEPARTMENT OF DEFENSE (DOD) MIL-V-12003 (Rev F; Am 1; CANC Notice 1) Valves, Plug, Cast-Iron or Steel, Manually Operated
U.S. GENERAL SERVICES ADMINISTRATION (GSA) CID A-A-1689 (Rev B) Tape, Pressure-Sensitive Adhesive, (Plastic Film) (Basic) Pumps, Centrifugal, Water Circulating, Electric-Motor-Driven (Basic) Unions, Brass or Bronze, Threaded SECTION 23 21 13.00 20 Page 3
CID A-A-50560
CID A-A-59617
123044
Pipe Connections and Solder-Joint Tube Connections FS WW-S-2739 (Basic; Notice 1) Strainers, Sediment: Pipeline, Water, Air, Gas, Oil, or Steam
U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA) 29 CFR 1910.144 Safety Color Code for Marking Physical Hazards Mechanical Power Transmission Apparatus
29 CFR 1910.219 1.2 RELATED REQUIREMENTS
Section 23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS applies to this section with additions and modifications specified herein. 1.3 SYSTEM DESCRIPTION
Except as specified otherwise, equipment and piping components shall be suitable for use in low temperature water heating system. Except as modified herein, the pressure temperature limitations shall be as specified in the referenced standards and specifications. Pressures in this specification are pressures in pounds per square inch above atmospheric pressure, and temperatures are in degrees Fahrenheit (F). 1.3.1 Hot Water Heating System Include the
Submit plan, elevations, dimensions, capacities, and ratings. following: a. b. c. db. ec. fd. ge. h. if. [jg. [k. [l. 1.4 Unit heaters Convectors Finned tube radiators Pumps Valves Expansion tanks Flow measuring equipment Backflow preventer Air separating tank Boilers] Hot water heat exchangers] Converters] SUBMITTALS
Government approval is required for submittals with a "G" designation; SECTION 23 21 13.00 20 Page 4
123044
submittals not having a "G" designation are [for Contractor Quality Control approval.][for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] The following shall be submitted in accordance with Section 01 33 00.05 20 CONSTRUCTION SUBMITTAL PROCEDURES: SD-02 Shop Drawings Hot water heating system SD-03 Product Data Convectors Finned tube radiators Pumps Include pump speed and characteristic curve for performance of impeller selected for each pump. Curves shall indicate capacity vs head, efficiency, and brake power for full range, from shut-off to free delivery. Expansion tanks Flow measuring equipment Backflow preventers External air separation tanks Hot water heating pipe SD-06 Test Reports Hydrostatic test of piping system Auxiliary equipment and accessory tests Submit test reports in accordance with the paragraph entitled "Field Quality Control." SD-07 Certificates Backflow preventer certification Report of prior installations Welding procedures Welder's qualifications SD-10 Operation and Maintenance Data Convectors, Data Package 3; G Finned tube radiators, Data Package 3; G Submit in accordance with Section 01 78 234.05 20 FACILITY SECTION 23 21 13.00 20 Page 5
123044
OPERATION AND MAINTENANCE DATASUPPORT INFORMATION. Submit a list of qualified service organizations which includes addresses and qualifications. 1.5 1.5.1 QUALITY ASSURANCE Standard Commercial Product for Terminal Units
Terminal units provided shall comply with features called out in this specification and shall be the manufacturer's standard commercial product. Additional or better features which are not prohibited by this specification but which are a part of the manufacturer's standard commercial product, shall be included in the terminal units being furnished. A standard commercial product is a product which has been sold or is currently being offered for sale, on the commercial market through advertisements or manufacturer's catalogs, or brochures. Provide Institute of Boiler and Radiator Manufacturer (IBR) or Steel Boiler Institute (SBI) rating for required capacity. 1.5.2 1.5.2.1 Welding Report of Prior Installations
Submit a Certificate of Full Approval or a current Certificate of Approval for each design, size, and make of backflow preventer being provided for the project. Certificate shall be from the Foundation for Cross-Connection Control and Hydraulic Research, University of Southern California, and shall attest that this design, size, and make of backflow preventer has satisfactorily passed the complete sequence of performance testing and evaluation for the respective level of approval. A Certificate of Provisional Approval is not acceptable in lieu of the above. 1.5.2.2 Welding Procedures
Before performing welding, submit three copies of welding procedure specification for all metals to be used in the work, together with proof of welder's qualification as outlines in ASME B31.9. 1.5.2.3 Welder's Qualifications
Before welder or operator performs welding, submit three copies of Welder's Performance Qualification Record in conformance with ASME B31.9showing that the welder was tested under the approved procedure specification submitted by the Contractor. In addition, submit each welder's assigned number, letter, or symbol used to identify the work of the welder. 1.5.2.4 Identification of Welder's Work
Ensure that each welder's assigned number, letter or symbol is affixed immediately upon completion of the weld. To welders making defective welds after passing a qualification test, give a requalification test. Upon failing to pass the test, do not permit welder to work in this contract. 1.5.2.5 Previous Qualifications
Welding procedures, welders, and welding operators previously qualified by test may be accepted for this contract without requalification subject to the approval and provided that all the conditions specified in ASME B31.9 are met before a procedure can be used. SECTION 23 21 13.00 20 Page 6
123044
1.5.3 1.5.3.1
Brazing and Soldering Brazing Procedure Brazing procedure for joints shall be as outlined in CDA A4015.
ASME B31.9. 1.5.3.2
Soldering, Soldering Preparation, and Procedures for Joints
ASME B31.9 and as outlined in CDA A4015. 1.5.4 Backflow Preventer Certification
Submit a Certificate of Full Approval or a current Certificate of Approval for backflow preventers. 1.6 1.6.1 SAFETY STANDARDS Welding
Safety in welding and cutting of pipe shall conform to AWS Z49.1. 1.6.2 Guards
Couplings, motor shafts, gears and other moving parts shall be guarded, in accordance with OSHA 29 CFR 1910.219. Guards shall be cast iron or expanded metal. Guard parts shall be rigid and removable without disassembling the guarded unit. PART 2 2.1 2.1.1 PRODUCTS PIPE AND FITTINGS Hot Water Heating Pipe (Supply and Return)
ASTM A53/A53M electric resistance welded or seamless Schedule [_____]40 steel pipe [or ASTM B88 Type [_____]K hard drawn Copper tubing]. 2.1.2 Fittings
Provide fittings compatible with the pipe being provided and shall conform to the following requirements. 2.1.2.1 Steel or Malleable Iron Pipe
Sizes 1/8 to 2 inches. ASME B16.11 steel socket welding or screwed type or ASME B16.3 for screwed type malleable iron fittings. 2.1.2.2 Steel, Cast Iron, or Bronze
Sizes 2 1/2 inches and above. Steel fitting butt welding type ASME B16.9 or ASME B16.5 flanged type. Cast iron fittings flanged type ASME B16.1. Bronze fittings up to 8 inch size flanged type ASME B16.24. 2.1.2.3 Fittings for Copper Tubing
ASME B16.18 cast bronze solder joint type or ASME B16.22wrought copper solder joint type. Fittings may be flared or compression joint type.
SECTION 23 21 13.00 20
Page 7
123044
2.1.3
Mechanical Pipe Coupling System
Couplings may be provided for water temperatures not to exceed 200 degrees F. Couplings shall be self centering and shall engage and lock in place the grooved or shouldered ends of pipe and pipe fittings in a positive watertight couple. Couplings shall be designed to permit some angular pipe deflection, contraction, and expansion. Coupling clamp shall be ductile iron conforming to ASTM A536, Grade 65-45-12. Gasket shall be molded rubber conforming to ASTM D 2000, the "line call-out" number shall be suitable for a water temperature of 230 degrees F. Coupling nuts and bolts shall be steel conforming to ASTM A183. Fittings shall be grooved malleable iron conforming to ASTM A47/A47M, Grade 32510 or ductile iron conforming to ASTM A536, Grade 65-45-12 or malleable iron conforming to ASTM A47/A47M, Grade 32510. Mechanical couplings and fittings shall be of the same manufacturer. Before assembling couplings, coat pipe ends and outsides of gaskets with lubricant approved by the coupling manufacturer to facilitate installation. 2.1.3.1 Groove and Check Valves
Grooved end, dual disc, spring loaded, non-slam check valves with Type 316 stainless steel or aluminum bronze discs and EPDM rubber seats. Maximum rated working pressure of 500 psi dependent on size. Tested in accordance with MSS SP-71. 2.1.3.2 Butterfly Valves
Grooved end butterfly valves with ductile iron body and disc core to ASTM A536. Disc rubber connected with EPDM rubber. Maximum rated working pressure of 300 psi tested in accordance with MSS SP-67. 2.1.3.3 Strainers
Include grooved end T-type strainers with steel or ductile iron bodies, Type 304 removable strainer baskets with 6 or 12 mesh screens and 57 percent open area. Maximum rated working pressure of 750 psi dependent on size. 2.1.3 2.1.3.1 Unions Steel Pipe
Provide ASME B16.39, malleable iron unions, threaded connections. 2.1.3.2 Copper Tubing
Provide CID A-A-59617, bronze unions, solder joint end. 2.1.3.3 Dielectric Union
Provide insulated union with galvanized steel female pipe-threaded end and a copper solder joint end conforming with ASME B16.39, Class 1, dimensional, strength and pressure requirements. Union shall have a water-impervious insulation barrier capable of limiting galvanic current to one percent of the short-circuit current in a corresponding bimetallic joint. When dry, insulation barrier shall be able to withstand a 600-volt breakdown test.
SECTION 23 21 13.00 20
Page 8
123044
2.1.4
Flanges
Remove raised faces when used with flanges having a flat face. 2.1.4.1 Steel Flanges
ASME B16.5 forged steel, welding type. 2.1.4.2 Cast Iron Screwed Flanges
ASME B16.1. 2.1.4.3 Bronze Screwed Flanges
ASME B16.24. 2.1.5 2.1.5.1 Drains and Overflows Steel Pipe
ASTM A53/A53M, [Electric resistance welded] [Seamless] Schedule 40, Malleable iron or forged steel fittings, screwed or welded joints. 2.1.5.2 Copper Tubing
ASTM B88, Type [K,] [L,] [M,] hard drawn, cast brass or wrought copper fittings, Grade Sb5 solder joints. 2.1.5.3 PVC Pipe
ASTM D 1785, Schedule 40, [and Schedule 80 for sizes 8 inch and larger,] solvent weld joints. 2.1.6 Valves
Valves shall have rising stems and shall open when turned counterclockwise. 2.1.6.1 a. Gate Valves
Bronze Gate Valves: MSS SP-80, 2 inches and smaller, wedge disc, inside screw type not less than Class 150. Use solder joint ends with copper tubing. Steel Gate Valves: ASME B16.34, provide with open stem and yoke type with solid wedge or flexible wedge disc and heat and corrosion-resistant steel trim. Cast Iron Gate Valves: MSS SP-70, 2 1/2 inches and larger, open stem and yoke type with bronze trim. Globe and Angle Valves
b.
c.
2.1.6.2 a.
Bronze Globe and Angle Valves: MSS SP-80, 2 inches and smaller, Class 200, except use Class 150 with solder ends for copper tubing. Valves shall have renewable seat and discs except solder end valves which shall have integral seats. Steel Globe and Angle Valves: corrosion-resistant trim. ASME B16.34, provide with heat and
b.
SECTION 23 21 13.00 20
Page 9
123044
c.
Cast Iron Globe and Angle Valves: MSS SP-85, 2 1/2 inches and larger, with bronze trim, tapped drains and brass plug. Check Valves
2.1.6.3 a.
Bronze Check Valves: MSS SP-80, 2 inches and smaller, regrinding swing check type, Class 200. Steel Swing Check Valves: Class 200. (1) (2) [ASME B16.34], regrinding swing check type,
b.
Swing check valves shall have bolted caps. Steel Lift check valves 2 inches and smaller shall have bolted caps. Lift check valves 2 1/2 inches and larger shall have pressure seal caps.
c.
Cast Iron Check Valves: ASME B16.34, 2 1/2 inches and larger, bronze trim, non-slam, eccentric disc type for centrifugal pump discharge service. Temperature Regulating Valves
2.1.6.4
Provide ASSE 1017 copper alloy body with adjustable range thermostat. 2.1.6.5 Water Pressure-Reducing Valves
ASSE 1003. 2.1.6.6 Plug Valves
MIL-V-12003, except that a replaceable valve seat will not be required. [ Type I - lubricated, tapered plug] [Type II - non-lubricated, lift-plug] valves. 2.1.6.7 Ball Valves
Flanged or butt-welding ends ball valve shall conform to MSS SP-72, [bronze ] [steel]. Threaded, socket-welding, solder joint, grooved and flared ends shall conform to MSS SP-110. 2.1.7.8 Radiator Valves
Radiator valves shall be angle or straightway pattern, with packed or packless bonnet shutoff globe type, designed especially for hot water heating system. Valve shall be constructed of brass or bronze or copper alloy conforming to ASTM specifications for materials with non-metallic renewable disc and plastic wheel handle for shutoff service. 2.1.6.8 Flow Control Balancing Valves
Copper alloy or cast iron body, copper alloy or stainless internal working parts, and integral pointer that indicates the degree of valve opening. Valves shall be suitable for 125 psig at 190 degrees F hot water. Valve shall function as a service valve when in fully closed position. Valve body shall have factory-installed tappings for differential pressure meter connections for verification of pressure differential across valve orifice. Meter connections shall have positive check valves or shutoff SECTION 23 21 13.00 20 Page 10
123044
valves. Each valve shall have metal tag showing the gallons per minute flow for each differential pressure reading. 2.1.6.9 Butterfly Valves
Conform with MSS SP-67, Type I - Tight shut off valve, and [flanged] [screwed] [single flange] [flangeless] valve ends. Valve body material shall be [cast iron] [steel] [bronze] and shall be bubble tight for shutoff at 150 psig. Flanged and flangeless type valves shall have Type 300 series corrosion resistant steel stems and corrosion resistant or bronze discs with molded elastomer disc seals. Flow conditions shall be for the regulation from maximum flow to complete shutoff by way of throttling effect. Valves shall be provided in [closed] [open] system. Valves smaller than 8 inches shall have throttling handles. Valves 8 inches and larger shall have totally enclosed manual gear operators with adjustable balance return stops and indicators. Valves shall have a minimum of 7 locking positions and shall be suitable for water temperatures up to 200 degrees F. 2.1.7.11 Butterfly Valves 2 Inches and Smaller
Valves shall be one-piece and three-piece design with male or female threaded or soldered end connections and shall be bubble tight for shutoff at 150 psig. Stem and disc assembly shall be of 300 series corrosion resistant steel. Disc seal assembly shall be of 300 series corrosion resistant steel. Disc seal shall be suitable for the liquid being used in the system in which the valve is to be installed. Valves shall be suitable for water temperature up to 200 degrees F and shall be capable of operating at the rated pressure of [_____] psig. Valves shall be designed for throttling service use by valve lever and indicator adjustment. 2.1.6.10 Relief Valves
Bronze body, teflonTeflon seat, stainless steel stem and springs, automatic, direct pressure actuated, capacities ASME certified and labelled labeled. 2.1.6.11 Valve Operating Mechanisms
Provide [floor stands] [chainwheels] [power operators] [ and extension stems ] where indicated and as specified. a. Floor Stands: Construct for bolting to the floor and include an extension stem and an operating handwheel. Design an adequately supported and guided extension stems for connection to the valve stem by a sleeve coupling or universal joint. Floor stands shall be cast iron or steel. Handwheel shall identify rotation direction for closing the valve and shall be of such diameter as to permit operation of the valve with a force of not more than 40 pounds. Chainwheel Operator: Shall be fabricated of cast iron or steel and shall include a wheel, endless chain and a guide to keep the chain on the wheel. Provide galvanized steel endless chain extending to within 3 feet of the floor. Power Operators: Shall be [electric] [pneumatic]. Power operated valves shall open and close at rates no slower than 10 inches per minute for gate valves and 4 inches per minute for globe and angle valves. Valves shall open fully or close tightly without requiring further SECTION 23 21 13.00 20 Page 11
b.
c.
123044
attention when the actuating control is moved to the open or close position. A predetermined thrust exerted on the stem during operation resulting from an obstruction in the valve shall cause the motor to automatically stop. Power operators shall be complete with all gearing and controls necessary for the size of valve being provided. Power operators shall be designed to operate on the [electric] [compressed air] power supply indicated. db. Extension Stem: Corrosion resisting steel designed for rising and non-rising stems. Provide in length required to connect the valve stem and the [handwheel] [operating mechanism] and of sufficient cross section to transfer the torque required to operate the valve. Balancing Valves
2.1.6.12
Balancing valves shall be calibrated bronze body balancing valves with integral ball valve and venturi or valve orifice and valve body pressure taps for flow measurement based on differential pressure readings. Valve pressure taps and meter connections shall have seals and built-in check valves with threaded connections for a portable meter. Meter shall be provided by the same manufacturer and be capable of reading system pressures and shall meet the requirements of the paragraph entitled "Flow Measuring Equipment." Valves shall have internal seals to prevent leakage around rotating element and be suitable for full shut-off rated pressure. Valves shall have an operator with integral pointer and memory stop. Balancing valves shall be selected for the required flows as indicated on the plans. 2.1.7 2.1.7.1 End Connections Flexible Connectors
Provide flexible pipe connectors on piping connected to equipment. Flexible section shall consist of rubber, tetrafluoroethylene resin, corrosion-resistant steel, bronze, monel, or galvanized steel. Material provided and configuration shall be suitable for [pressure,] [vacuum,] [ temperature,] and circulating medium. Flexible section shall have [threaded,] [welding,] [soldering,] [flanged] [or] [socket-weld] ends and shall be suitable for service intended. Flexible section may be reinforced with metal retaining rings, with built-in braided wire reinforcement and restriction bolts or with wire braid cover suitable for service intended. 2.1.7.2 Steel Piping
Screwed or socket welded for 2 inches and smaller and flanged or butt welded for 2 1/2 inches and larger. a. b. Screwed Joints With Taper Threads: Flanged Joints: (1) ASME B1.20.1.
Bolting and gaskets shall be as follows:
Bolting: Bolt and stud material ASTM A307, Grade B, and nut material ASTM A194/A194M, Grade 2. Bolt, stud, and nut dimensions ASME B18.2.2 threads ASME B1.1coarse type with Class 2A fit for bolts and studs, and Class 2B fit for nuts. Bolts or bolt studs shall extend completely through the nuts and may have reduced shanks of a diameter not less than the diameter at root of threads. Carbon steel bolts shall have American Standard regular square or heavy hexagon heads and shall have American Standard SECTION 23 21 13.00 20 Page 12
123044
heavy semifinished hexagonal nuts conforming to ASME B18.2.2. (2) Gaskets: ASME B16.21, Nonasbestos compressed material 1/16 inch thickness full face or self-centering flat ring type and suitable for pressure and temperature of the piping system.
c.
Butt Weld Joints: ASME B31.9. Backing rings shall conform to ASME B31.9. Ferrous rings shall not exceed 0.05 percent sulfur; for alloy pipe, backing rings shall be of material compatible with the chemical composition of the parts to be welded and preferably of the same composition. Provide continuous machined or split band backing rings. Socket Weld Joints: ASME B31.9. Joints for Copper Tubing Solder and flux
d.
2.1.7.3 a.
Solder conforming to ASTM B32 alloy grade Sb5 or Sn96. shall be lead free (less than 0.2 percent of lead).
b.
Copper Tube Extracted Joint: An extracted mechanical tee joint may be made in copper tube. Make joint with an appropriate tool by drilling a pilot hole and drawing out the tube surface to form a collar having a minimum height of three times the thickness of the tube wall. To prevent the branch tube from being inserted beyond the depth of the extracted joint, provide dimpled depth stops. Notch the branch tube for proper penetration into fitting to assure a free flow joint. Braze extracted joints using a copper phosphorous classification brazing filler metal. Soldered joints shall not be permitted. Expansion Joints PacklessFlexible Loop Type
2.1.8 2.1.8.1
Provide ASTM F 1120, Type III with fabricated corrosion-resistant steel bellows.Flexible loops shall consist of two flexible sections of hose and braid, two, 90 degree elbows, and an 180 degree return assembled in such a way that the piping does not change direction, but maintains its course along a single axis. Flexible loops shall have a factory supplied, center support nut located at the bottom of the 180 degree return, and a drain/air release plug. Flexible loops shall impart no thrust loads to system support anchors or building structure. Loops shall be installed in a neutral, pre-extended condition as required for the application. Install and guide in accordance with manufacturer's recommendations. Materials of construction and end fitting type shall be consistent with pipe material and equipment/pipe connections fittings. Braided hose section shall consist of carbon steel, copper or stainless steel ends, connecting braze or weldment, and connection shall be encased in a stress relieving weld collar. Hose shall be stainless steel or bronze flexible metallic hose encased in a stainless steel or bronze braid. Rubber hose materials are prohibited. 2.1.9.2 Guided Slip-Tube Type
Provide ASTM F 1007, Type IV internally-externally guided, injected semiplastic type packing.
SECTION 23 21 13.00 20
Page 13
123044
2.1.9 2.1.9.1
Instrumentation Pressure and Vacuum Gauges
Provide ASME B40.100 with restrictor. 2.1.9.2 Indicating Thermometers
Thermometers shall be dial type with an adjustable angle suitable for the service. Provide thermowell sized for each thermometer in accordance with the thermowell specification. Fluid-filled thermometers (mercury is not acceptable) shall have a nominal scale diameter of 5 inches. Construction shall be stainless-steel case with molded glass cover, stainless-steel stem and bulb. Stem shall be straight, length as required to fit well. Bimetal thermometers shall have a scale diameter of 3 1/2 inches. Case shall be hermetic. Case and stem shall be constructed of stainless steel. Bimetal stem shall be straight and of a length as required to fit the well. 2.1.9.3 Pressure/Temperature Test Ports
Pressure/Temperature Test Ports shall have brass body and EPDM and/or Neoprene valve seals. Ports shall be rated for service between 35 and 275 degrees F and up to 500 psig. Ports shall be provided in lengths appropriate for the insulation thickness specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS and installed to allow a minimum of 12 inches of access for probe insertion. Provide with screw-on cap attached with a strap or chain to prevent loss when removed. Ports shall be 1/4 inch NPT and accept 1/8 inch diameter probes. 2.1.10 2.1.10.1 Miscellaneous Pipeline Components Air Vent
Provide float type air vent in hydronic systems. Vent shall be constructed of brass or semi-steel body, copper float, and stainless steel valve and valve seat. Design air vent to suit system operating temperature and pressure. Provide isolating valve to permit service without draining the system. Pipe discharge of vent to a drain. 2.1.10.2 Strainers
Strainers for classes 125 and 250 piping in IPS 1/2 to 8 inches, inclusive, FS WW-S-2739 and locate as indicated. 2.1.10.3 Hangers and Supports
Design and fabrication of pipe hangers, supports, and welding attachments shall conform to MSS SP-58 and ASME B31.9. Hanger types and supports for bare and covered pipe shall conform to MSS SP-69 for the temperature range. 2.1.10.4 Pipe Sleeves
Sleeves in masonry and concrete walls, floors, and roof slabs shall be ASTM A53/A53M, Schedule 40 or Standard Weight, hot-dip galvanized steel [ductile-iron or cast-iron] pipe. Sleeves in partitions shall be zinc-coated sheet steel having a nominal weight of not less than 0.906 pound per square foot.
SECTION 23 21 13.00 20
Page 14
123044
2.1.10.5
Escutcheon Plates
Provide one piece or split hinge metal plates for piping passing through floors, walls, and ceilings in exposed spaces. Provide polished stainless steel plates or chromium-plated finish on copper alloy plates in finished spaces and paint finish on metal plates in unfinished spaces. 2.2 CENTRAL MECHANICAL EQUIPMENT Boilers
[2.2.1
Provide as specified in [Section 23 52 43.00 20 LOW PRESSURE WATER HEATING BOILERS UNDER 800,000 BTU/HR OUTPUT][Section 23 52 46.00 20 LOW PRESSURE WATER HEATING BOILERS OVER 800,000 BTU/HR OUTPUT]. ][2.2.2 Hot Water Heat Exchangers
Provide as specified in Section 23 21 13.23 20 [HIGH] [MEDIUM] TEMPERATURE WATER SYSTEM WITHIN BUILDINGS. ][2.2.3 Converters
Steam to hot water converters shall conform to FS WW-H-191 and shall have capacity as indicated for the design conditions. The converters shall be designed for support by separate pipe hangers, and [temperature regulator] [vent valve] shall be provided. ]2.3 2.3.1 PIPING SYSTEM EQUIPMENT Pumps
Provide hot water circulating pumps, CID A-A-50560, Service A. Pump casing and flange shall be made of close-grained cast iron. Shaft shall be carbon or alloy steel with lubricated bearings and impeller shall be bronze. Select pumps so that the operating point on selected impeller-curve will lie at or to the left of shutoff side of, and not more than 5 percent below, point of maximum efficiency for impeller. Provide motors of [open] [splash proof] [totally enclosed] type conforming to NEMA MG 1 and suitable for electrical characteristic as indicated. Motor starters shall conform to NEMA ICS 2 [manual] [across the line] [reduced-voltage-start] [part-wind] [wye-delta] type with NEMA ICS 6[ general purpose] [weather-resistant] [watertight] enclosure. 2.3.2 Expansion Tanks
Provide welded steel, constructed and tested hydrostatically in accordance with ASME BPVC SEC VIII D1. Tank shall be equipped with all necessary fittings. The tank and fittings shall be pressure rated at least equal to the test pressure of the total system. Zinc coat the tank inside and out after fabrication by the hot dip process ASTM A123/A123M.
2.3.3
External Air Separation Tanks
Provide tank constructed of steel, designed for not less than 75 psig, and constructed and tested in accordance with the requirements of ASME BPVC SEC VIII D1. Provide tangential inlet and outlet connections, flanged for sizes 2 1/2 inches and larger. Each unit shall have an SECTION 23 21 13.00 20 Page 15
123044
internal design suitable for creating the required vortex and subsequent air separation. Provide with automatic air release device and galvanized steel strainer. Provide a blow down connection with a gate valve and piped to nearest floor drain. 2.3.4 Backflow Preventers
Reduced pressure principle type. Furnish proof that each make, model/design, and size of backflow preventer being furnished for the project is approved by and has a current "Certificate of Approval" from the [FCCCHR List] [or] [local code]. Listing of a particular make, model/design, and size in the current [FCCCHR List] [or] [local code] will be acceptable as the required proof. 2.3.4 Flow Measuring Equipment
Orifice or venturi type. Flow metering equipment including pitot tubes, venturis, orifice plates, flanges, and indicating meters shall be the product of one and the same manufacturer. Provide flowmeters of [permanent type] [or] [portable type] [type indicated]. Flowmeters shall be suitable for service in which they are to be installed. Primary elements of flowmeters shall conform to ASME recommendations for flowmeters. Provide bronze, monel, or stainless steel materials for wetted parts of flow meters. a. Orifices: Square-edge type, made of corrosion and erosion resistant metal and mounted between pipe flanges having factory-made pressure taps provided with shutoff valves. Orifice flanges shall conform to ASME B16.36. Tubular Flowmeters: Flow measuring elements consisting of venturi tubes or pitot tubes where indicated. Locations and arrangement of piping, both upstream and downstream of flow measuring elements shall conform to the manufacturer's published literature. Provide each flow measuring element with an integral tab, or a metal tag on a corrosion-resistant steel wire, extending outside pipe covering, and stamped or printed in a visible position with manufacturer's name and address; serial number of meter to which it is to be connected; name, number, or location of equipment served; specified rate of flow; and multiplier to be applied to meter reading. Provide taps with shutoff valves and quick connecting hose fittings for portable meters or double ferrule compression fittings for connection to tubing for permanently located meters or recorders. Tubes shall be calibrated in accordance with ASME recommendations. (1) Venturi Tubes: Certified by the manufacturer for the actual piping configuration and any necessary piping changes required for certification without additional cost to the Government. Throat diameter for each venturi tube shall be designed so that at specified rate of flow the scale reading will fall between 50 percent and 80 percent of full scale value. Select venturi tube sizes from the manufacturer's latest published tables of flow versus differential pressure. Unrecovered head loss at maximum flow shall not exceed 10 percent. Provide bronze or cast iron tubes with bronze-lined throats, with flanged, threaded, or welded ends to suit piping system. Provide bodies of fabricated steel and fittings of the same class as piping in which installed. Two integral meter taps shall be provided in each venturi tube. Connections for attachment to portable flow meter hoses shall be readily accessible and not over 6 feet above a floor or permanent SECTION 23 21 13.00 20 Page 16
b.
123044
platform. (2) Pitot Tube Assemblies: Provide corrosion-resistant materials. Tubes shall be capable of measuring liquid flow through tube elements providing an averaged, interpolated flow measurement from a single, fixed position. Provide self cleaning elements and impact tube designed to rotate when turned by the operator to protect pressure-sensing elements of tube when not in use. Location and total amount of pitot tubes required for system flow measurement shall be as recommended by the manufacturer and as indicated.
c.
Meters: Designed for a full scale pressure differential of 50 inches water gage for tubular type or 100 inches water gage for orifice type. Dials shall have square root or linear scales with developed length of not less than 12 inches. Provide flush mounted panel meters that read directly in gallons per minute. Dials of portable meters shall have square root scales reading from 0 to 100 gpm for use with multiplier stamped on orifice or tubular type. Provide meters designed for not less than 200 psi and protected against pressure surges. Meter bodies shall have taps for venting and draining. (1) Permanently Mounted Meters: Each meter shall be connected completely [as indicated] [and] [as specified] and provided with the following: three valve manifold equalizer lines, two block valves, two vent and drain valves, and an integral pulsation damper. Overall accuracy of meters shall be plus or minus 2 percent of full scale flow over a range from 20 to 100 percent of full scale flow. Portable Meters: Provide meter with a factory-fabricated carrying case with carrying handle. Provide case fitted to hold meter securely and to accommodate the following accessories: (a) Two 15 foot lengths of connecting hose with suitable female connectors for connecting from meter to [venturi tube] [orifice flange] [pitot tube] pressure-tap nipples. Provide hose designed for a minimum service pressure of 125 psi or 150 percent of maximum system service pressure, whichever is greater. (b) A completely assembled three-valve manifold with two block valves and vent and drain valves, piped and mounted on a base designed for use laying flat on a stationary surface. (c) A bound set of descriptive bulletins, installation and operating instructions, parts list, and a set of curves showing flow versus pressure differential for each orifice, venturi tube, or pitot tube with which meter is to be used. (d) A metal instruction plate, secured inside cover, illustrating use of meter. (e) Provide meters with overall accuracy of plus or minus 5 percent of full scale flow over a range from 20 to 100 percent of full scale flow.
(2)
SECTION 23 21 13.00 20
Page 17
123044
2.4 2.4.1
TERMINAL UNITS Finned Tube Radiators
[Steel tube and steel fin type FS S-R-2834]. [Copper tube and aluminum fin type CID A-A-50545, [shall have an adjustable damper].] 2.4.2 Convectors
CID A-A-50543 and CID A-A-50544, of design and capacity not less than that indicated. 2.4.1 Unit Heaters
Provide hot water unit heaters as specified in Section 23 82 00.00 20 TERMINAL HEATING AND COOLING UNITS.Heaters shall be designed for suspension and arranged for horizontal discharge of air as indicated. Casings shall be not less than 20 gauge black steel and finished with lacquer or enamel. Suitable stationary deflectors shall be provided to assure proper air and heat penetration capacity at floor level based on established design temperature. Suspension from heating pipes will not be permitted. Heating coils shall be as specified in Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEM for types indicated. Coils shall be suitable for use with water up to 250 degrees F. 2.4.4 Heating and Ventilating Units
Provide fan-coil units, induction units, unit ventilators, and gravity ventilators as specified in Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS. 2.5 ELECTRICAL EQUIPMENT
Provide complete with motors, motor starters, thermal overload protection, and controls. Equipment and wiring shall be in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. 2.6 CONTROLS
Provide controls as specified in Section 23 09 23.13 22 BACnet DIRECT DIGITAL CONTROL SYSTEMS FOR HVACSPACE TEMPERATURE CONTROL SYSTEMS. 2.7 INSULATION
Provide shop and field applied insulation as specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. 2.8 ASBESTOS PROHIBITION
Asbestos and asbestos containing products are prohibited. PART 3 3.1 EXECUTION PREPARATION
Provide storage for equipment and material at the project site. All parts shall be readily accessible for inspection, repair, and renewal. Protect material and equipment from the weather. SECTION 23 21 13.00 20 Page 18
123044
3.2
INSTALLATION
Piping fabrication, assembly, welding, soldering, and brazing shall conform to ASME B31.9. Piping shall follow the general arrangement shown. Route piping and equipment within buildings out of the way of lighting fixtures and doors, windows, and other openings. Run overhead piping in buildings in inconspicuous positions. Provide adequate clearances from walls, ceilings, and floors to permit welding of joints and application of insulation. Make provision for expansion and contraction of pipe lines. Make changes in size of water lines with reducing fittings. Do not bury, conceal, or insulate until piping has been inspected, tested, and approved. Do not run piping concealed in walls, partitions, underground, or under the floor except as otherwise indicated. Where pipe passes through building structure, locate pipe joints and expansion joints where they may be inspected. Provide flanged joints where necessary for normal maintenance and where required to match valves and equipment. Furnish gaskets, packing, and thread compounds suitable for the service. Provide long radius ells where possible to reduce pressure drops. Pipe bends in lieu of welding fittings may be used where space permits. Pipe bends shall have a uniform radius of at least five times the pipe diameter and shall be free from appreciable flattening, wrinkling, or thinning of the pipe. Do not use mitering of pipe to form elbows, notching straight runs to form full sized tees, or any similar construction. Make branch connections over 2 inches with welding tees except factory made forged welding branch outlets or nozzles having integral reinforcements conforming to ASME B31.9 may be used, provided the nominal diameter of the branch is at least one pipe size less than the nominal diameter of the run. Branch connections 2 inches and under can be threaded or welded. Run vertical piping plumb and straight and parallel to walls. Provide sleeves for lines passing through building structure. Provide a fire seal where pipes pass through fire wall, fire partitions, fire rated pipe chase walls, or floors above grade. Install piping connected to equipment with flexibility for thermal stresses and for vibration, and support and anchor so that strain from weight and thermal movement of piping is not imposed on the equipment. 3.2.1 Hangers and Supports
Unless otherwise indicated, horizontal and vertical piping attachments shall conform to MSS SP-58. Band and secure insulation protection shields without damaging pipe insulation. Continuous inserts and expansion bolts may be used. 3.2.2 Grading of Pipe Lines
Unless otherwise indicated, install horizontal lines of hot water piping to grade down in the direction of flow with a pitch of not less than one inch in 30 feet, except in loop mains and main headers where the flow may be in either direction. 3.2.3 Pipe Sleeves
Provide sleeves where pipes and tubing pass through masonry or concrete walls, floors, roof, and partitions. Annular space between pipe, tubing, or insulation and the sleeve shall not be less than 1/4 inch. Hold sleeves securely in proper position and location before and during construction. Sleeves shall be of sufficient length to pass through entire thickness of walls, partitions, or slabs. Sleeves in floor slabs shall extend 2 inches above finished floor. Firmly pack space between pipe or tubing and sleeve SECTION 23 21 13.00 20 Page 19
123044
with oakum and caulk on both ends of the sleeve with plastic waterproof cement which will dry to a firm but pliable mass, or provide a [ mechanically adjustable] segmented elastomeric seal. Seal both ends of penetrations through fire walls and fire floors to maintain fire resistive integrity with UL listed fill, void, or cavity material. 3.2.4 Flashing for Buildings
Provide flashing where pipes pass through building roofs, and make outside walls tight and waterproof. 3.2.5 Unions and Flanges
Provide unions and flanges to permit easy disconnection of piping and apparatus. Each connection having a screwed-end valve shall have a union. Place unions and flanges no farther apart than 100 feet. Install unions downstream of valves and at equipment or apparatus connections. Provide unions on piping under 2 inches in diameter, and provide flanges on piping 2 inches and over in diameter. Provide dielectric unions or flanges between ferrous and non-ferrous piping, equipment, and fittings; except that bronze valves and fittings may be used without dielectric couplings for ferrous-to-ferrous or non-ferrous-to-non-ferrous connections. 3.2.6 Connections for Future Equipment
Locate capped or plugged outlets for connections to future equipment as indicated. 3.2.7 Changes in Pipe Size
Provide reducing fittings for changes in pipe size; reducing bushings are not permitted. In horizontal lines, provide eccentric reducing fittings to maintain the top of the lines in the same plane. 3.2.8 Cleaning of Pipe
Thoroughly clean each section of pipe, fittings, and valves free of foreign matter before erection. Prior to erection, hold each piece of pipe in an inclined position and tap along its full length to loosen sand, mill scale and other foreign matter. For pipe 2 inches and larger, draw wire brush, of a diameter larger than that of the inside of the pipe, several times through the entire length of pipe. Before making final connections to apparatus, wash out interior of piping thoroughly with water. Plug or cap open ends of mains during shutdown periods. Do not leave lines open where foreign matter might enter the pipe. 3.2.9 Valves
Install valves in conformance with ASME B31.9. Provide gate valves unless otherwise directed. Install valves with stems horizontal or above. Locate or equip stop valves to permit operation from floor level, or provide with safe access in the form of walkways or ladders. Install valves in positions accessible for operation and repair. 3.2.9.1 Globe Valves
Install globe valves so that the pressure is below the disk and the stem horizontal.
SECTION 23 21 13.00 20
Page 20
123044
3.2.9.2
Radiators Valves
Provide radiator valves on water inlet and balancing valves on water outlet of terminal heating units such as radiation, unit heaters, and fan coil unit. 3.2.9.3 Relief Valves
Provide valves on pressure tanks, low pressure side of reducing valves, heat exchangers, and expansion tanks. Select system relief valve so that capacity is greater than make-up pressure reducing valve capacity. Select equipment relief valve capacity to exceed rating of connected equipment. Pipe relief valve outlet to the nearest floor drain. 3.2.10 Pressure Gage
Provide a shut-off valve or pet cock between pressure gages and the line. 3.2.11 Thermometers
Provide thermometers and thermal sensing elements of control valves with a separable socket. Install separable sockets in pipe lines in such a manner to sense the temperature of flowing the fluid and minimize obstruction to flow. 3.2.12 Strainers
Provide strainers, with meshes suitable for the services, where indicated, or where dirt might interfere with the proper operation of valve parts, orifices, or moving parts of equipment. 3.2.13 Pumps
Select pumps for specified fluid temperatures, are non-overloading in parallel or individual operation, and operate within 25 percent of midpoint of published maximum efficiency curve. Support piping adjacent to pump such that no weight is carried on pump casings. Install close coupled and base mounted pumps on concrete base, with anchor bolts, set and level, and grout in place and provide supports under elbows on pump suction and discharge line sizes 4 inches and over. Lubricate pump before start-up. 3.2.14 Equipment Foundations
Locate equipment foundations as shown on the drawings. Size, weight, and design shall preclude shifting of equipment under operating conditions. Foundations shall meet the requirements of the equipment manufacturer. Concrete shall conform to Section 03 30 00 CAST-IN-PLACE CONCRETE, and grout shall be approved non-shrinking. 3.2.15 Equipment Installation
Install equipment in accordance with installation instructions of the manufacturers. Grout equipment mounted on concrete foundations before installing piping. Install piping in such a manner as not to place a strain on the equipment. Do not bolt flanged joints tight unless they match. Grade, anchor, guide, and support piping without low pockets.
SECTION 23 21 13.00 20
Page 21
123044
3.2.16
Cleaning of Systems
As installation of the various system components is completed, fill, start, and vent prior to cleaning. Place terminal control valves in open position. Add cleaner to closed system at concentration as recommended by manufacturer. Apply heat while circulating, slowly raising temperature to 160 degrees F and maintain for 12 hours minimum. Remove heat and circulate to 100 degrees F or less; drain systems as quickly as possible and refill with clean water. Circulate for 6 hours at design temperatures, then drain. Refill with clean water and repeat until system cleaner is removed. Use neutralizer agents on recommendation of system cleaner supplier and approval of Contracting Officer. Remove, clean, and replace strainer screens. Inspect, remove sludge, and flush low points with clean water after cleaning process is completed. Include disassembly of components as required. Preliminary or final tests are not permitted until cleaning is approved. 3.2.17 Painting of Piping and Equipment
Provide in accordance with Section 09 90 00 PAINTS AND COATINGS. 3.2.18 Identification of Piping
Identify piping in accordance with OSHA 29 CFR 1910.144, except that labels or tapes may be used in lieu of painting or stenciling. Spacing of identification marking on runs shall not exceed 50 feet. Materials for labels and tapes shall conform to CID A-A-1689, and shall be general purpose type and color class. Painting and stenciling shall conform to Section 09 90 00 PAINTS AND COATINGS. 3.3 FIELD QUALITY CONTROL
Perform inspections and tests as specified herein to demonstrate that piping and equipment, as installed, is in compliance with contract requirements. Start up and operate the system. During this time, periodically clean the various strainers until no further accumulation of foreign material occurs. Exercise care so that minimum loss of water occurs when strainers are cleaned. Adjust safety and automatic control instruments to place them in proper operation and sequence. 3.3.1 Hydrostatic Test of Piping System
Test piping system hydrostatically using water not exceeding 100 degrees F. Conduct tests in accordance with the requirements of ASME B31.9 and as follows. Test piping system after all lines have been cleaned and before applying insulation covering. Remove or valve off from the system, gages, and other apparatus which may be damaged by the test before the tests are made. Install calibrated test pressure gage in the system to observe any loss in pressure. Maintain test pressure for a sufficient length of time to enable an inspection of each joint and connection. Perform tests after installation and prior to acceptance.Notify the Contracting Officer in writing [_____]10 days prior to the time scheduled for the tests. 3.3.2 Auxiliary Equipment and Accessory Tests
Observe and check pumps, accessories, and equipment during operational and capacity tests for leakage, malfunctions, defects, noncompliance with referenced standards, or overloading.
SECTION 23 21 13.00 20
Page 22
123044
3.3.2.1
Backflow Preventers
Backflow preventers shall be tested by locally approved and certified backflow assembly testers. A copy of the test report shall be provided to the Contracting Officer prior to placing the domestic water system into operation, or no later than 5 days after the test. 3.4 TESTING, ADJUSTING, AND BALANCING SMACNA 1780, and specifications; adjust, and balance TESTING, ADJUSTING
[Except as specified herein, perform in accordance with Chapter VIII "Hydronic System TAB Procedures," drawings prepare complete report of final test results.] [Test, the hydronic system in accordance with Section 23 05 93 AND BALANCING FOR HVAC.] 3.4.1 Markings of Settings
Following final acceptance of the balancing report, the settings of all valves, splitters, dampers, and other adjustment devices shall be permanently marked so that adjustment can be restored if disturbed at anytime. 3.4.2 Sound Level Tests
Upon completion of testing and balancing of hydronic systems, conduct sound level tests of conditioned spaces. Use sound level meter required by ASA S1.4, Type 2, calibrated in accordance with NBS standards and guidelines, and accompanied by a certificate of calibration. Record sound levels in dBA with heating systems off and with heating systems operating. Record the following data for each room and system: a. b. c. Background sound level (systems off); Total sound level corrected for background; and Sound power rating by manufacturer of the respective outlet.
Test Locations: Take sound level reading at location 6 feet from face of each outlet on a line at 45 degrees with face of outlet. Remedial Action: If sound level at any observation point exceeds [20] [45] [_____] dBA, take remedial action as directed.
SECTION 23 21 13.00 20
Page 23
123044
SECTION 23 25 00 CHEMICAL TREATMENT OF WATER FOR MECHANICAL SYSTEMS 11/08 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. ASME INTERNATIONAL (ASME) ASME B40.100 (2005) Pressure Gauges and Gauge Attachments
ASTM INTERNATIONAL (ASTM) ASTM D 596 (2001; R 2011) Reporting Results of Analysis of Water
1.2
SYSTEM DESCRIPTION
This section covers the provisions and installation procedures necessary for a complete and totally functional water system(s) chemical treatment. Provide and install the system with all necessary System Components, Accessories, Piping Components, and Supplemental Components/Services. 1.3 SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for [Contractor Quality Control approval.][information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] Submit the following in accordance with Section 01 33 00.05 20.05 20 CONSTRUCTION SUBMITTAL PROCEDURES: SD-03 Product Data Water Treatment System[; G][; G, [_____]] Water Analysis[; G][; G, [_____]] Spare Parts Field Instructions Tests[; G ][; G, [_____]] Training Course[; G][; G, [_____]] SD-06 Test Reports Condenser Water QA Tests Steam Boiler Water QA Tests SD-10 Operation and Maintenance Data Water Treatment System SECTION 23 25 00 Page 1
123044
1.4 1.4.1
QUALITY ASSURANCE Safety
Exposed moving parts, parts that produce high operating temperature, parts which may be electrically energized, and parts that may be a hazard to operating personnel shall be insulated, fully enclosed, guarded, or fitted with other types of safety devices. Install safety devices so that proper operation of equipment is not impaired. Provide [catwalk,] [ladder,] [and guardrail] where indicated and in accordance with Section [05 50 13 MISCELLANEOUS METAL FABRICATIONS] [05 51 33 METAL LADDERS]. 1.4.2 Drawings
Because of the small scale of the drawings, it is not possible to indicate all offsets, fittings, and accessories that may be required. Carefully investigate the plumbing, fire protection, electrical, structural and finish conditions that would affect the work to be performed and arrange such work accordingly, furnishing required offsets, fittings, and accessories to meet such conditions. 1.5 DELIVERY, STORAGE, AND HANDLING
Protect all equipment delivered and placed in storage from the weather, humidity and temperature variations, dirt and dust, or other contaminants. 1.6 MAINTENANCE
Submit spare parts data for each different item of material and equipment specified, after approval of the detail drawings, not later than [_____]3 months prior to the date of beneficial occupancy. The data shall include a complete list of parts and supplies, with source of supply PART 2 2.1 PRODUCTS STANDARD PRODUCTS a. Provide materials and equipment which are standard products of a manufacturer regularly engaged in the manufacturing of such products, that are of a similar material, design and workmanship and that have been in satisfactory commercial or industrial use for two years prior to bid opening. b. The two-year use shall include applications of equipment and materials under similar circumstances and of similar size. The two years experience shall have been satisfactorily completed by a product which has been sold or is offered for sale on the commercial market through advertisements, manufacturer's catalogs, or brochures. Products having less than a two-year field service record will be acceptable if a certified record of satisfactory field operation, for not less than 6000 hours exclusive of the manufacturer's factory tests, can be shown. c. All products shall be supported by a service organization. Submit a certified list of qualified permanent service organizations for support of the equipment, including their addresses and qualifications. These service organizations shall be reasonably convenient to the equipment installation and shall be able to render SECTION 23 25 00 Page 2
123044
satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract. d. The selected service organization shall provide the chemicals required, the concentrations required, and the water treatment equipment sizes and flow rates required. The company shall provide all chemicals required for the [condenser] [condenserBoiler and chilled] water systems and fill the systems with chemicals to the levels specified. The chemical shall meet the requirements of this specification as well as the recommendations from the manufacturers of the condenser and cooling tower. Acid treatment chemicals shall not be used. 2.2 NAMEPLATES
Each major component of equipment shall have the manufacturer's name, address, type or style, and catalog or serial number on a plate securely attached to the item of equipment. Nameplates shall be provided for: a. b. 2.3 Pump(s) Pump Motor(s)
ELECTRICAL WORK
Electrical equipment, motors, motor efficiencies, and wiring shall be in accordance with Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Provide electrical motor driven equipment specified complete with motors, motor starters, and controls. Electrical characteristics and enclosure type shall be as shown, and unless otherwise indicated, all motors of 1 horsepower and above with open, dripproof, or totally enclosed fan cooled enclosures, shall be high efficiency type. Field wiring shall be in accordance with manufacturer's instructions. Each motor shall conform to NEMA MG 1 and be of sufficient size to drive the equipment at the specified capacity without exceeding the nameplate rating of the motor. All motors shall be continuous duty with the enclosure specified. Provide motor starters complete with thermal overload protection and other appurtenances necessary for the motor control indicated. Furnish motors with a magnetic across-the-line or reduced voltage type starter as required by the manufacturer. Motor starter shall be provided with [NEMA 1] [NEMA 3R] [NEMA [_____]] enclosures. Manual or automatic control and protective or signal devices required for the operation specified and any control wiring required for controls and devices specified, but not shown, shall be provided. 2.3 GAUGES
Gauges shall conform to ASME B40.100, Class 1, 2, or 3, Style X, Type I or III as required, 4-1/2 inches in diameter with phenolic or metal case. 2.4 WATER ANALYSIS
Conditions of make-up water to be supplied to the boilers, condenser water heat reclaim system, cooling towers and chilled water systems reported in accordance with ASTM D 596 are as follows: Date of Sample Temperature Silica (SiO 2) SECTION 23 25 00 [_____] [_____] degrees C. [_____] ppm (mg/L) Page 3
123044
Insoluble Iron, total (Fe) Aluminum (Al) Calcium (Ca) Magnesium (Mg) Carbonate (HCO 3) Sulfate (SO 4) Chloride (Cl) Nitrate (NO 3) Turbidity pH Residual Chlorine Total Alkalinity Non-Carbonate Hardness Total Hardness Dissolved Solids Conductivity 2.6 CONDENSER WATER TREATMENT SYSTEMS
[_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____]
ppm ppm ppm ppm ppm ppm ppm ppm ppm ntu
(mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L) (mg/L)
ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) micromho/cm
The use of chemical-treatment products containing hexavalent chromium (Cr) is prohibited. Treat the water to be used in the condenser water systems to maintain the conditions recommended by this specification as well as the recommendations from the manufacturers of the condenser and evaporator coils. Chemicals shall meet all required federal, state, and local environmental regulations for the treatment of condenser-side heat exchangers, cooling towers and direct discharge to the sanitary sewer. 2.6.1 Condenser Water Limits
The condenser water limits shall be as follows, unless dictated differently by the cooling tower or chiller manufacturer's recommendations: Treatment type Puckorius Index Langelier Index Total Dissolved Solids Calcium Hardness Silica PH Phosphonate/Polymer 4 minimum 4 maximum 5000 ppm maximum 1200 ppm maximum 150 ppm maximum 7.5 - 8.5
For treated condenser/cooling tower water, blowdown must be minimized until the first of one of the top 5 limits is reached. Specific requirements for treatment chemicals and levels are listed below in paragraphs dealing with small and large systems. 2.6.2 Glycol Solution
Provide for the system a [_____] percent concentration by volume of industrial grade [ethylene] [propylene] glycol, and corrosion inhibitors. Test the glycol in accordance with ASTM D 1384 with less than 0.5 mils penetration per year for all system metals. The glycol shall contain corrosion inhibitors. Silicate based inhibitors are not acceptable. The solution shall be compatible with pump seals, other elements of the system, and water treatment chemicals used within the system. 2.6.3 Chemical Treatment for Small Systems
For cooling systems with a capacity of 50 tons or less, provide the SECTION 23 25 00 Page 4
123044
following chemical treatment. For corrosion control provide 15 to 20 pounds polyphosphate in nylon mesh bag in cooling tower sump. If biocide is needed, use either 1-bromo-3-chloro-5.5-dimethylhydantoin or gluteraldehyde as recommended by manufacturer. 2.6.4 Chemical Treatment for Large Systems
For cooling systems with capacities greater than 50 tons provide one of the three following chemical treatments with the limits indicated. The zinc and molybdate in the last two treatments help to meet the maximum corrosion requirements in waters that tend to be more corrosive. Biocides must be maintained to control bacteria below 10,000 colony forming units per milliliter. a. Phosphonate Type Treatment Phosphonate Polymer TT Biocides b. (3-5 ppm) (3-4 ppm) (1-2 ppm) as required
Zinc-Phosphonate Type Treatment Phosphonate Polymer Zinc TT Biocides (3-5 ppm) (3-4 ppm) (1-2 ppm) (1-2 ppm) as required
c.
Zinc-Molybdate Type Treatment Phosphonate Polymer Molybdate Zinc TT Biocides (3-5 ppm) (3-4 ppm) (10-15 ppm) (2-3 ppm) (1-2 ppm) as required
2.6.4.1
General Requirements
Provide a water treatment system capable of automatically feeding chemicals and bleeding the system to prevent corrosion, scale, and biological formations. Submit [6] [_____] complete copies, at least 5 weeks prior to the purchase of the water treatment system, of the proposed water treatment plan including a layout; control scheme; a list of existing make-up water chemistry, including the items listed in paragraph Water Analysis; a list of treatment chemicals to be added; the proportion of chemicals to be added; the final treated water control levels; and a description of health, safety and environmental concerns for handling the chemicals plus any special ventilation requirements. Automatic chemical feed systems shall automatically feed chemicals into the condenser water based on makeup water rate. Electrical signals from a water meter on the makeup water line shall be used to control the output of chemical feed pumps. The system shall be initially set manually based on the water analysis of the make-up water. Submit [6] [_____] complete copies of operating and maintenance manuals for the step-by-step water treatment procedures. The manuals shall include testing procedures used in determining water quality.
SECTION 23 25 00
Page 5
123044
2.6.4.2
Chemical Feed Pumps and Tanks
a. Furnish chemical feed pumps and tanks as a package with the pumps mounted on and piping connected to the tank. The chemical feed pumps shall be positive displacement diaphragm type. The pump's cylinders, plungers, ball check valves, and check valve bodies shall be of corrosion resistant materials suitable for the chemicals being pumped. Cylinders shall be replaceable for increased or reduced pressure or capacity ranges. b. The flow rate of the pumps shall be adjustable from 0 to 100 percent while in operation. Volumetric accuracy of the pumps shall be within one percent over the range indicated. Pump capacities shall be adjustable by positioning crank pin with micrometer setscrews. Stroke length scale shall be divided in percentage graduations engraved on scale. The discharge pressure of pumps shall not be less than 1.5 times the line pressure at the point of connection. The pumps shall be provided with a pressure relief valve and a check valve mounted in the pump discharge. The pumps shall be controlled by an external controller/timer receiving signals from the makeup water meter. c. Drive motors shall be 110 volt, single phase and shall have drip-proof enclosures. Provide two chemical tanks. The tanks shall be constructed of [materials compatible with the chemicals to be stored in the tank] [high density polyethylene] [stainless steel] [fiber reinforced plastic] with a hinged cover and mounted on legs. Tanks shall have filling and drain connections and gauge glass. Each tank shall be furnished with one pump, mounted and piped with black iron pipe and fittings, with suction strainer and stainless steel screen, and with 1/2 inch relief valve with steel body and stainless steel trim. Tank bottom shall be dished concave to a radius equal to the diameter of the tank. Motor-driven agitator shall be provided. The tanks shall have sufficient capacity to require recharging only once per [7] [14] [21] [_____] days during normal operation. 2.6.4.3 Chemical Injection Assembly
Provide an injection assembly at each chemical feed point. Locate the injection assembly downstream of recirculating pumps and upstream of the condenser. The injection assemblies shall be constructed of stainless steel. The discharge of the assemblies shall extend to the centerline of the condenser water piping. Each assembly shall include a shutoff valve and check valve at the point of entrance into the condenser water line. 2.6.4.4 Water Meter
Provide water meters with an electric contacting register and remote accumulative counter. Install the meter within the make-up water line, as indicated. 2.6.4.5 Timers
Timers shall be of the automatic reset, adjustable type, and electrically operated. The timers shall be designed to work with the contacting head water meters. The timer should include the water meter cable. The timers will control operation of the chemical feed pumps. The timers shall be suitable for a 120 volt current. The timers shall be located within the water treatment control panel.
SECTION 23 25 00
Page 6
123044
2.6.4.6
Bleed (Blowdown) Line
Control the flow through the bleed line by a conductivity meter and probe installed to measure the conductivity of the condenser water. The conductivity meter shall have a high and low set point above which the conductivity meter shall open a solenoid valve on the bleed line. The bleed line attachment to the condenser water piping shall be located downstream of the recirculating pumps and upstream of the chemical injection point. The bleed line shall be extended to the nearest drain for continuous discharge. 2.6.4.7 Control Panel
The control panel shall be a NEMA 12 enclosure suitable for surface mounting. The panel shall be constructed of [stainless steel] [coated steel] with a hinged door and lock. The panel shall contain a laminated plastic nameplate identifying each of the following functions: (1) (2) (3) (4) (5) 2.6.4.8 Main power switch and indicating light MAN-OFF-AUTO selector switch Indicating lamp for bleed-off valve Indicating lamp for each chemical feed pump Set point reading for each timer
Chemical Piping
The piping and fittings shall be constructed of [schedule 80 PVC] [stainless steel] suitable for the water treatment chemicals. 2.6.4.9 Sequence of Operation
The chemicals shall be added based upon sensing the make-up water flow rate and activating appropriate timers. A separate timer shall be provided for each chemical. The blow down shall be controlled based upon the conductivity of the condenser water. The injection of the chemical required for biological control shall be controlled by a timer that can be manually set for proper chemical feed. All timer set points, blow down rates, and chemical pump flow rates shall be determined and set by the water treatment company. 2.6.4.10 Test Kits
One test kit of each type required to determine the water quality as outlined within the operation and maintenance manuals shall be provided. 2.5 CHILLED WATER SYSTEM
A [2] [5] [_____] gallon shot feeder shall be provided on the chilled water piping as indicated. The feeder shall be furnished with an air vent, gauge glass, funnel, valves, fittings, and piping. 2.7.1 Requirements for Glycol Solution
Provide a [_____] percent concentration by volume of industrial grade [ethylene] [propylene] glycol, and corrosion inhibitors, for the system. Test the glycol in accordance with ASTM D 1384 with less than 0.5 mils penetration per year for all system metals. The glycol shall contain corrosion inhibitors. Silicate based inhibitors shall not be used. The solution shall be compatible with pump seals, other elements of the system, SECTION 23 25 00 Page 7
123044
and water treatment chemicals used within the system. 2.5.1 Chilled Water Treatment
Treat chilled water with either a borax/nitrite type treatment or a molybdate type treatment. Both types of treatment can be used with glycol. Borax/nitrite treatment shall be maintained at the limits of 600 to 1000 ppm nitrite, 40 - 50 ppm copper corrosion inhibitor (TT or MBT), and pH of 8.5 to 9.5. Molybdate treatment shall be maintained at the limits of 100 to 125 ppm molybdate, 40 - 50 ppm copper corrosion inhibitor (TT or MBT), and pH of 8.0 to 9.0. 2.7.3 Dual Temperature Systems
Dual hot/chilled water systems treated with borax/nitrite shall also be treated with a biocide. 2.5.2 Chilled Water Test Kits
One test kit of each type required to determine the water quality as outlined within the operation and maintenance manuals shall be provided (e.g. pH and nitrite or molybdate). 2.6 LOW AND MEDIUM TEMPERATURE HOT WATER BOILERS AND HEAT EXCHANGERS
Low and medium temperature hot water boilers are defined as those operating below 350 degrees F, ( 250 degrees F for Low Temperature). 2.6.1 Chemical Feeder
A [2] [5] [_____] gallon shot feeder shall be provided on the hot water piping as indicated. Size and capacity of feeder shall be based on local requirements and water analysis. The feeder shall be furnished with an air vent, gauge glass, funnel, valves, fittings, and piping. 2.8.2 Water Softening System
The water softening system shall be as specified in Section 22 31 00 WATER SOFTENERS, CATION-EXCHANGE (SODIUM CYCLE). 2.6.2 Low and Medium Temperature Hot Water Treatment
Hot water shall be treated with either a borax/nitrite type treatment or a molybdate type treatment. Both types of treatment can be used with glycol. Borax/nitrite treatment shall be maintained at the limits of 600 to 1000 ppm nitrite, 40 - 50 ppm copper corrosion inhibitor (TT or MBT) and pH of 8.5 to 9.5. Molybdate treatment shall be maintained at the limits of 100 to 125 ppm molybdate, 40 - 50 ppm copper corrosion inhibitor (TT or MBT) and pH of 8.0 to 9.0. 2.8.4 Dual Temperature Systems
Dual hot/chilled water systems treated with borax/nitrite shall also be treated with a biocide. 2.6.3 Test Kit Requirements
One test kit of each type required to determine the water quality as outlined within the operation and maintenance manuals shall be provided SECTION 23 25 00 Page 8
123044
(e.g. pH and nitrite or molybdate). 2.9 2.9.1 HIGH TEMPERATURE HOT WATER BOILERS Chemical Feeder Unit
A feeder unit shall be provided for each boiler. Chemical feeder shall be automatic proportioning, shot type, or pump type. All appurtenances necessary for satisfactory operation shall be provided. Size and capacity of feeder shall be based upon local requirements and water analysis. 2.9.2 Pumps and Tanks a. Furnish chemical feed pumps and tanks as a package with the pumps mounted on and piping connected to the tank. The chemical feed pumps shall be positive displacement diaphragm type. The pump cylinders, plungers, ball check valves, and check valve bodies shall be of corrosion resistant materials suitable for the chemicals being pumped. Cylinders shall be replaceable for increased or reduced pressure or capacity ranges. b. The flow rate of the pumps shall be adjustable from 0 to 100 percent while in operation. Volumetric accuracy of the pumps shall be within one percent over the range indicated. Pump capacities shall be adjustable by positioning crank pin with micrometer setscrews. Stroke length scale shall be divided in percentage graduations engraved on scale. The discharge pressure of pumps shall not be less than 1.5 times the line pressure at the point of connection. The pump shall be designed to feed the chemical solutions into the HTW return line to the system circulating pumps and shall have capacity to feed a maximum of [5] [_____] gph. The pumps shall be provided with a pressure relief valve and a check valve mounted in the pump discharge. The pumps shall be controlled by an external controller/timer receiving signals from the makeup water meter. c. Drive motors shall be 110 volt, single phase and shall have drip-proof enclosures. The tanks shall be constructed of [materials compatible with the chemicals to be stored in the tank] [high density polyethylene] [stainless steel] [fiber reinforced plastic] with a hinged cover and mounted on legs. Tanks shall have filling and drain connections and gauge glass. Each tank shall be furnished with one pump, mounted and piped with black iron pipe and fittings, with suction strainer and stainless steel screen, and with 1/2 inch relief valve with steel body and stainless steel trim. Tank bottom shall be dished concave to a radius equal to the diameter of the tank. Units shall be for phosphate, caustic feed and sulfite feeding. Sulfite tank shall have a floating cover to completely cover the surface of the solution. Motor-driven agitator shall be provided. The tanks shall have sufficient capacity to require recharging only once per [7] [14] [21] [_____] days during normal operation. 2.9.3 Water Softening System
The water softening system shall be as specified in Section 22 31 00 WATER SOFTENERS, CATION-EXCHANGE (SODIUM CYCLE). 2.9.4 Treated Water Limits
The boiler manufacturer shall be consulted for the determination of the SECTION 23 25 00 Page 9
123044
boiler water chemical composition limits. The recirculating hot water chemical limits shall be as follows unless dictated differently by the boiler manufacturer's recommendations: PH Sulfite Hardness 2.7 Test Kit 9.3-9.9 30-60 ppm Less than 2.0 ppm
One test kit of each type required to determine the water quality as outlined within the operation and maintenance manuals shall be provided (e.g. pH, hardness and sulfite). 2.11 STEAM BOILER WATER TREATMENT
Provide a water treatment system capable of feeding chemicals and blowdown of the system to prevent corrosion and scale within the boiler and piping distribution system. Treat the water to maintain the conditions recommended by the boiler manufacturer or UFC 3-230-08A (Central Boiler Plants) and PWTB 420-49-5 (Industrial Water Treatment Procedures). Chemicals shall meet required federal, state, and local environmental regulations for the treatment of boilers and discharge to the sanitary sewer. The services of a company regularly engaged in the treatment of boilers shall be used to determine the correct concentrations required for water treatment. The company shall maintain the chemical treatment and provide all chemicals required for a period of 1 year from the date of occupancy. Filming amines, hydrazine and chelants shall not be used. The water treatment chemicals shall remain stable throughout the operating temperature range of the system and shall be compatible with pump seals and other elements of the system. 2.11.1 Boiler Water Limits
The boiler water limits shall be as follows unless dictated differently by the boiler manufacturer's recommendations: Causticity (OH) Total Alkalinity (CaCO3) Phosphate (PO4) Polymer (dispersant) or Tannin Dissolved Solids (water tube boilers) Dissolved Solids (fire tube boilers) Suspended Solids Sodium Sulfite Silica Dissolved Oxygen Iron pH (Condensate) Conductivity (Condensate) Hardness (Condensate and makeup) 20-200 ppm 200-800 ppm 30-60 ppm 5-10 ppm or medium color, respectively 3000-3500 ppm 3500-5000 ppm 15 ppm Maximum 20-40 ppm Less than 200 ppm Less than 7 ppb Less than 10 ppm 7.5 - 8 Less than 35 micromhos Less than 2 ppm
The above limits apply to boilers operating above 15 psi up 300 psi. Above 300 psi these limits decrease. Use ABMA or chemical vendor recommended limits above 300 psi.
SECTION 23 25 00
Page 10
123044
2.11.2
Water Softening System
The water softening system shall be as specified in Section 22 31 00 WATER SOFTENERS, CATION-EXCHANGE (SODIUM CYCLE). 2.11.3 Boiler Water Treatment System
The water treatment system shall be capable of automatically feeding chemicals to prevent corrosion and scale within the boiler and condensate system. Automatic chemical feed systems shall feed chemicals into the boiler based on makeup water rate. Electrical signals from a water meter on the makeup water line shall be used to control the output of chemical feed pumps. 2.11.4 Steam Boiler Chemical Feed Pumps and Tanks a. Furnish chemical feed pumps and tanks as a package with the pumps mounted on and piping connected to the tank. The chemical feed pumps shall be positive displacement diaphragm type. The pump cylinders, plungers, ball check valves, and check valve bodies shall be of corrosion resistant materials suitable for the chemicals being pumped. Cylinders shall be replaceable for increased or reduced pressure or capacity ranges. The flow rate of the pumps shall be adjustable from 0 to 100 percent while in operation. Volumetric accuracy of the pumps shall be within one percent over the range indicated. Pump capacities shall be adjustable by positioning crank pin with micrometer setscrews. Stroke length scale shall be divided in percentage graduations engraved on scale. b. The discharge pressure of pumps shall not be less than 1.5 times the line pressure at the point of connection. The pumps shall be provided with a pressure relief valve and a check valve mounted in the pump discharge. The pumps shall be controlled by an external controller/timer receiving signals from the makeup water meter. c. Drive motors shall be 110 volt, single phase and shall have drip-proof enclosures. The tanks shall be constructed of [materials compatible with the chemicals to be stored in the tank] [high density polyethylene] [stainless steel] [fiber reinforced plastic] with a hinged cover and mounted on legs. Tanks shall have filling and drain connections and gauge glass. Each tank shall be furnished with one pump, mounted and piped with black iron pipe and fittings, with suction strainer and stainless steel screen, and with 1/2 inch relief valve with steel body and stainless steel trim. Tank bottom shall be dished concave to a radius equal to the diameter of the tank. The tank for sodium sulfite will have a floating cover to minimize contact with air. Motor-driven agitator shall be provided. The tanks shall have sufficient capacity to require recharging only once per [7] [14] [21] [_____] days during normal operation. 2.11.5 Steam Boiler Chemical Injection Assemblies
Provide an injection assembly at each chemical injection point located along the boiler piping as indicated. The injection assemblies shall be constructed of stainless steel. The discharge of the assemblies shall extend to the centerline of the piping. Each assembly shall include a shutoff valve and check valve at the point of entrance into the water line.
SECTION 23 25 00
Page 11
123044
2.11.6
Steam Boiler Water Meter
Provide the water meter with an electric contacting register and remote accumulative counter. Install the meter within the makeup water line, as indicated. 2.11.7 Steam Boiler Timers
Timers shall be of the automatic reset, adjustable type, and electrically operated. The timers shall be designed to work with the contacting head water meters. The timer should include the water meter cable. The timers will control operation of the chemical feed pumps. The timers shall be suitable for a 120 volt current. The timers shall be used to control the electrical signals from the water meters to the chemical feed pumps. 2.11.8 Steam Boiler Control Panel
The control panel shall be a NEMA 12, single door, wall-mounted box conforming with NEMA 250. The panel shall be constructed of [coated steel] [stainless steel] with a hinged door and lock. The panel shall contain, as a minimum, the following functions identified with a laminated plastic nameplate: a. b. c. d. 2.11.9 Main power switch and indicating light MAN-OFF-AUTO selector switch Indicating lamp for each chemical feed pump Indicating lamp for the water softener
Boiler Blowdown
Provide the boiler with [continuous blowdown] [automatic blowdown based upon conductivity or boiler load]. Bottom blowdown connection and valve shall also be present to allow removal of solids and water from the bottom of the boiler. 2.11.10 Boiler Chemical Piping
The piping and fittings shall be constructed of [steel] [stainless steel]. 2.11.11 Boiler Test Kits
One test kit of each type required to determine the water quality as outlined in paragraph Boiler Water Limits above and within the operation and maintenance manuals. 2.8 SUPPLEMENTAL COMPONENTS/SERVICES
Drain and makeup water piping shall comply with the requirements of Section 22 00 00 PLUMBING, GENERAL PURPOSE. Drains which connect to sanitary sewer systems shall be connected by means of an indirect waste. PART 3 3.1 EXECUTION EXAMINATION
After becoming familiar with all details of the work, verify all dimensions in the field, and advise the Contracting Officer of any discrepancy, before performing any work.
SECTION 23 25 00
Page 12
123044
3.2
INSTALLATION
Provide all chemicals, equipment and labor necessary to bring all system waters in conformance with the specified requirements. Perform all work in accordance with the manufacturer's published diagrams, recommendations, and equipment warranty requirements. 3.3 PIPING
Connections between dissimilar metals shall be made with a dielectric union. 3.4 TRAINING COURSE
Submit a schedule, at least 2 weeks prior to the date of the proposed training course, that identifies the date, time, and location for the training. Conduct a training course for the operating staff as designated by the Contracting Officer. The training period shall consist of a total [_____] hours of normal working time and start after the system is functionally completed but prior to final acceptance tests. Submit field instructions, at least 2 weeks prior to construction completion, including equipment layout, wiring and control diagrams, piping, valves and control sequences, and typed condensed operation instructions. The condensed operation instructions shall include preventative maintenance procedures, methods of checking the system for normal and safe operation, and procedures for safely starting and stopping the system. The posted instructions shall be framed under glass or laminated plastic and posted where indicated by the Contracting Officer. The field instructions shall cover all of the items contained in the Operation and Maintenance Manuals as well as demonstrations of routine maintenance operations. 3.4 TESTS
If the waters of the mechanical systems are not in conformance with the specified requirements or in accordance with manufacturer's recommendations, the water treatment company shall take corrective action to enable compliance. Daily operational tests shall be performed in the directed frequencies to maintain required control to prevent corrosion, scaling and damage to equipment during operation Submit test schedules, at least 2 weeks prior to the start of related testing, for the condenser/ chilled/boiler/condensate/feedwater water quality tests. The schedules shall identify the date, time, frequency and collection location for each test. 3.5.1 3.5.1.1 Condenser Water Quality Tests Small Systems (weekly)
Once a week, for cooling systems with a capacity of 50 tons or less, the following items shall be recorded. PH Total Alkalinity (as CaCO3) Conductivity 3.5.1.2 Tests for Large Systems (daily) [_____] [_____] ppm (mg/L) [_____] micromho/cm
Daily, for cooling systems with a capacity larger than 50 tons, the following items shall be recorded.
SECTION 23 25 00
Page 13
123044
PH Total Alkalinity (as CaCO3) Conductivity Phosphonate Zinc, if used (Zn) Molybdate, if used (Mo) 3.4.1 Chilled Water Testing (monthly)
[_____] [_____] [_____] [_____] [_____] [_____]
ppm (mg/L) micromho/cm ppm (mg/L) ppm (mg/L) ppm (mg/L)
Once a month, the following tests will be performed on chilled water. PH Nitrite or Molybdate Conductivity 3.4.2 3.4.2.1 [_____] [_____] ppm (mg/L) [_____] micromho/cm
Hot Water Boiler Water Quality Testing Low and Medium Temperature Systems (monthly)
Monthly testing shall be completed and recorded for the following parameters. PH Nitrite or Molybdate 3.5.3.2 [_____] [_____] ppm (mg/L)
High Temperature Hot Water Systems (daily)
Daily testing shall be completed and recorded for the following parameters. PH Sulfite (Na2SO3) Hardness 3.5.4 3.5.4.1 Steam Boiler Water Testing Small Steam Systems [_____] [_____] ppm (mg/L) [_____] ppm (mg/L)
The type of treatment required for small steam systems (below 25 hp) varies greatly depending on local water and system conditions. The type of treatment and frequency of testing shall be determined by the water treatment chemical vendor. 3.5.4.2 Medium Steam Systems (twice weekly)
Twice a week for steam boiler systems operating between 25 hp and 100 hp the following items will be recorded and utilized for operation purposes. PH P Alkalinity (as CaCO3) Total Dissolved Solids Phosphate (PO4) Sulfite (NaSO3) 3.5.4.3 Large Steam Systems (daily) [_____] [_____] [_____] [_____] [_____]
ppm ppm ppm ppm
(mg/L) (mg/L) (mg/L) (mg/L)
Daily, for steam boiler systems operating above 15 psi and 100 hp, the following items will be recorded and utilized for operational purposes. Sulfite (NaSO3) SECTION 23 25 00 [_____] ppm (mg/L) Page 14
123044
P Alkalinity (as CaCO3) Conductivity Neutralized Conductivity Total Dissolved Solids Phosphate (PO4) Condensate pH Condensate Conductivity Condensate Hardness (as CaCO3) Makeup Water Hardness (as CaCO3) 3.4.3 Quality Assurance Testing
[_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____]
ppm (mg/L) micromho/cm micromho/cm ppm (mg/L) ppm (mg/L) micromho/cm ppm (mg/L) ppm (mg/L)
Conduct QA testing periodically by an independent water treatment lab/consultant to verify to managers that the mechanical and water treatment systems are being maintained properly. Provide the QA evaluation reports to the government COR. 3.5.5.1 Condenser Water QA Tests
Submit test reports in bound 8-1/2 by 11 inch booklets. The reports shall identify the chemical composition of the condenser water. The reports shall also include a comparison of the manufacturer's or chemical vendor's recommended operating conditions for the cooling tower and condenser in relation to the actual condition of the condenser water. Any required corrective action shall be documented within the report. a. For cooling systems with a capacity of 50 ton or less, the following tests shall be performed Presence of scale/corrosion Polyphosphate Biocide PH Total Alkalinity (as CaCO3) Calcium Hardness (as CaCO3) Conductivity Written evaluation summary [_____] [_____] [_____] [_____] [_____] [_____] [_____]
ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) micromho/cm
b. For cooling systems with capacities greater than 50 ton), the condenser water shall be analyzed a minimum of once a month for a period of one year by the water treatment company. The analysis shall include the following information recorded in accordance with ASTM D 596. Date of Sample Temperatures (before & after condenser) pH Silica (SiO2) Iron (total, as Fe(2)O(3)) Copper (Cu) Calcium Hardness(CaCO3) Total Hardness (as CaCO3) Chloride (Cl) Total Alkalinity (as CaCO3) Conductivity Total Dissolved Solids Phosphonate (as PO4) Zinc (if used) (Zn) Molybdate (if used) (Mo) Tolyltriazole (TT) SECTION 23 25 00 [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____]
[_____] degrees C. ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) micromho/cm ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L)
Page 15
123044
Biocide Bacteria colony count Makeup water pH Makeup water Iron Makeup water Silica Makeup water Calcium Hardness Makeup water Total Hardness Makeup water Total Alkalinity Makeup water Chloride (Cl) Makeup water Conductivity Written evaluation summary 3.4.3.1
[_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____]
ppm (mg/L) colonies/mL ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) micromho/cm
Chilled Water Quality Assurance Testing (quarterly)
Quarterly, the following tests shall be performed on chilled water. PH Nitrite or Molybdate Conductivity Iron (total, as Fe(2)O(3)) Written evaluation summary 3.4.3.2 [_____] [_____] ppm (mg/L) [_____] micromho/cm [_____] ppm (mg/L)
Hot Water Boiler Water Quality Assurance Testing
a. Quarterly testing of Low and Medium Temperature Systems shall be completed and recorded for the following parameters. PH Nitrite or Molybdate Iron (total, as Fe(2)O(3)) Written evaluation summary [_____] [_____] ppm (mg/L) [_____] ppm (mg/L)
b. The hot water boiler water shall be analyzed once a month for a period of 1 year by an independent consultant. The analysis shall include the following information recorded in accordance with ASTM D 596. PH Sulfite (Na2SO3) Hardness(as CaCO3) Iron (total, as Fe(2)O(3)) Written evaluation summary 3.5.5.4 Steam Boiler Water QA Tests [_____] [_____] ppm (mg/L) [_____] ppm (mg/L) [_____] ppm (mg/L)
Submit the water quality test report identifying the chemical composition of the boiler, feedwater and condensate water. The report shall include a comparison of the condition of the boiler water with the manufacturer's or chemical vendor's recommended conditions. Any required corrective action shall be documented within the report. a. Small and Medium Steam Boiler Systems (quarterly)are systems operating between 25 hp and 100 hp. The following tests shall be performed quarterly. pH Sulfite, if used, (NaSO3) P Alkalinity (as CaCO3) Total Dissolved Solids Phosphate, if used, (PO4) SECTION 23 25 00 Page 16 [_____] [_____] [_____] [_____] [_____]
ppm ppm ppm ppm
(mg/L) (mg/L) (mg/L) (mg/L)
123044
Polymer, if used Iron (total, as Fe(2)O(3)) Condensate pH Condensate Conductivity Condensate Hardness (as CaCO3) Condensate Iron (total, as Fe(2)O(3)) Makeup Water Hardness (as CaCO3) Written evaluation summary
[_____] [_____] [_____] [_____] [_____] [_____] [_____]
ppm (mg/L) ppm (mg/L) micromho/cm ppm (mg/L) ppm (mg/L) ppm (mg/L)
b. Large steam boilers are those operating above 15 psi and 100 hp. The boiler water shall be analyzed a minimum of once a month for a period of 1 year by an independent consultant. The analysis shall include the following information recorded in accordance with ASTM D 596. Date of Sample pH Sulfite (NaSO3) P Alkalinity (as CaCO3) Conductivity Neutralized Conductivity Total Dissolved Solids Phosphate (PO4) Polymer Silica (SiO2) Iron (total, as Fe(2)O(3)) Condensate pH Condensate Conductivity Condensate Hardness (as CaCO3) Condensate Iron (total, as Fe(2)O(3)) Makeup Water Hardness (as CaCO3) Written evaluation summary 3.5.6 Corrosion Testers [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____]
ppm (mg/L) ppm (mg/L) micromho/cm micromho/cm ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) ppm (mg/L) micromho/cm ppm (mg/L) ppm (mg/L) ppm (mg/L)
Install corrosion coupon and rack systems to verify corrosion control in the systems. Testers or coupons are installed in flowing system water through a sidestream or rack system. Both mild steel and copper metal samples are to be tested in the corrosion testers in accordance with ASTM D 2688. Samples are to be replaced and analyzed every 3 months. Rates of corrosion less than 3 mpy for steel and 0.2 mpy for copper are acceptable. Corrosion testers shall be installed on the piping systems of the following systems. Condenser loop Chilled water system Hot water loop Condensate 3.6 3.6.1 INSPECTIONS Inspection General Requirements
Thirty days after project completion, inspect the cooling tower and condenser for problems due to corrosion, scale, and biological growth. If the cooling tower and condenser are found not to conform to the manufacturer's recommended conditions, and the water treatment company recommendations have been followed; the water treatment company shall provide all chemicals and labor for cleaning or repairing the equipment as required by the manufacturer's recommendations. SECTION 23 25 00 Page 17
123044
3.6.2
Boiler/Piping Test
Thirty day after project completion, inspect the boiler and condensate piping for problems due to corrosion and scale. If the boiler is found not to conform to the manufacturer's recommendations, and the water treatment company recommendations have been followed, the water treatment company shall provide all chemicals and labor for cleaning or repairing the equipment as required by the manufacturer's recommendations. If corrosion is found within the condensate piping, proper repairs shall be made by the water treatment company. -- End of Section --
SECTION 23 25 00
Page 18
123044
SECTION 23 52 43.00 20 LOW PRESSURE WATER HEATING BOILERS (UNDER 800,000 BTU/HR OUTPUT) 07/06 PART 1 GENERAL
1.1 REFERENCES The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) ANSI Z21.13/CSA 4.9 (2010; Addenda A 2010) Gas-Fired Low Pressure Steam and Hot Water Boilers (1971; R 1995) Gas Utilization Equipment in Large Boilers
ANSI Z83.3
ASME INTERNATIONAL (ASME) ASME BPVC SEC IV (2010) BPVC Section IV-Rules for Construction of Heating Boilers (2009) Control and Safety Devices for Automatically Fired Boilers
ASME CSD-1
ASTM INTERNATIONAL (ASTM) ASTM A53/A53M (2010) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA MG 1 (2009) Motors and Generators
U.S. DEPARTMENT OF DEFENSE (DOD) MIL-B-18897 (Rev F; CANC Notice 1) Boilers, Steam and Hot Water, Watertube (Straight Bare and Finned Tube), Cast Iron and Firebox, Packaged Type (40,000 to 35,000,000 BTU/HR Thermal Output Capacity)
U.S. ENVIRONMENTAL PROTECTION AGENCY (EPA) Energy Star (1992; R 2006) Energy Star Energy Efficiency Labeling System
U.S. GENERAL SERVICES ADMINISTRATION (GSA) FS F-F-2901 Feeders, Boiler Water Treatment, By-Pass and Compound Receiver Types
SECTION 23 52 43.00 20
Page 1
123044
UNDERWRITERS LABORATORIES (UL) UL 795 (2011) Standard for Commercial-Industrial Gas Heating Equipment
1.2
Section 23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS, applies to this section, with the additions and modifications specified herein. 1.3 DESIGN REQUIREMENTS
Boiler shall be suitable for installation in the space shown with ample room for opening doors and cleaning and removal and replacement of tubes. Boiler shall have an output and of [_____]379 BTU/hr with an efficiency not less than that shown on drawings recommended by [Energy Star][FEMP]. Boiler shall be designed, tested, and installed in accordance with ASME BPVC SEC IV and ASME CSD-1. Paint boiler in accordance with manufacturer's recommendations. Boiler design working pressure shall be [ 30 psig] [_____]. Boiler operating pressure shall be [12 psig] [_____]. Boiler operating temperature shall be [180140 degrees F] [_____]. Boiler return water temperature shall be [1610 degrees CF] [_____]. Provide a thermostatically controlled three-way mixing valve on boiler suitable for operating conditions of the boiler. 1.3.1 Detail Drawings
Submit fuel train and wiring diagram 1.3.2 Water Analysis
Provide test reports of water analysis. 1.4 SAFETY STANDARDS
Hot water boilers, burners and supplementary control devices, safety interlocks, or limit controls required under this specification, shall meet requirements of the following standards as applicable: a. ba. c. Oil-Fired Units: Gas-Fired Units: UL 726. ANSI Z83.3, ANSI Z21.13/CSA 4.9 or UL 795. UL 726, ANSI Z83.3,
Combination Gas- and Oil-Fired Units: ANSI Z21.13/CSA 4.9 or UL 795. All Units:
db.
ASME BPVC SEC IV and ASME CSD-1.
Controls not covered by the above shall have a UL label, UL listing mark, or shall be listed in the Factory Mutual Approval Guide. 1.5 SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are [for Contractor Quality Control approval.][for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] The following shall be submitted in accordance with Section 01 33 00.05 20 CONSTRUCTION SUBMITTAL PROCEDURES: SECTION 23 52 43.00 20 Page 2
123044
[ Submittals for this Section shall be delivered to the Contracting Officer, who shall forward two complete sets of copies to the Commanding Officer, Southern Division, Naval Facilities Engineering Command, Code 16B, for review and approval.] SD-02 Shop Drawings Fuel train Wiring diagram SD-03 Product Data Boilers: power output, thermal efficiency, ASME certification, allowable working pressure, model number, documentation for Energy Star qualifications or meeting FEMP requirements Boiler trim and control equipment Burners and control equipment Stack, breeching, and supports [ Local/Regional Materials Documentation indicating distance between manufacturing facility and the project site. Indicate distance of raw material origin from the project site. Indicate relative dollar value of local/regional materials to total dollar value of products included in project.] [ Environmental Data] SD-06 Test Reports Operational tests Water analysis SD-07 Certificates Boilers Burners and control equipment Boiler trim and control equipment Boilers Boiler trim and control equipment Burners and control equipment Boiler manufacturer's certificate of boiler performance including evidence that the burners provided shall be a make, model, and type certified and approved by the manufacturer of the boiler being provided.
SECTION 23 52 43.00 20
Page 3
123044
SD-08 Manufacturer's Instructions Boilers Feedwater treatment feeder SD-10 Operation and Maintenance Data Boilers, Data Package 4 Submit in accordance with Section 01 78 234.05 20 FACILITY OPERATION AND MAINTENANCE DATASUPPORT INFORMATION. SD-11 Closeout Submittals Posted operating instructions for heating water boilers 1.6 1.6.1 SUSTAINABLE DESIGN REQUIREMENTS Local/Regional Materials
Use materials or products extracted, harvested, or recovered, as well as manufactured, within a [500][_____] mile radius from the project site, if available from a minimum of three sources. 1.6.2 Environmental Data
[Submit Table 1 of ASTM E 2129 for the following products: [_____].] PART 2 2.1 PRODUCTS BOILERS
MIL-B-18897. Provide hot water heating boiler complete with firing equipment, combustion chamber, insulation with steel jacket, safety and operating controls, integral pump electrical wiring, and other appurtenances, to make the boiler a complete, self-contained, fully-automatic unit, ready for service upon completion of utility connections. [Boilers less than 300,000 Btuh shall have an Annual Fuel Utilization Efficiency (AFUE) of at least [85][87] percent.] [Gas fired boilers greater than 300,000 Btuh output shall have a steady state combustion efficiency of at least 80 percent when fired at the maximum and minimum capacities which are provided and allowed by the controls.] [Oil fired boilers greater than 300,000 Btuh output shall have a steady state combustion efficiency of at least 83 percent when fired at the maximum and minimum rated capacities which are provided and allowed by the controls.] The boilers shall be of a water tube design. The boilers shall bear the ASME "H" stamp for 80 psi working pressure and shall be National Board listed. The heat exchanger assembly shall be fully welded through an automated process to ensure weld integrity. The 439 stainless steel combustion chamber and tubes shall be self cleaning and designed to drain condensation to the bottom of the heat exchanger assembly. A built-in stainless steel flue collector shall allow condensation to drain from the heat exchanger assembly and into the external condensate trap. The complete heat exchanger assembly shall carry a twelve (12) year limited warranty. The boilers shall be certified and listed by C.S.A. International under the latest edition of the harmonized ANSI Z21.13 /CSA4.9 test standard for the SECTION 23 52 43.00 20 Page 4
123044
U.S. and Canada. The boilers shall comply with the energy efficiency requirements of the latest edition of the ASHRAE 90.1 Standard and the minimum efficiency requirements of the latest edition of the ASHRAE 103 Standard. The boilers shall operate at a minimum of 95% Thermal Efficiency. The boilers shall be certified for indoor installation. The boilers's efficiency ratings shall be verified through third party testing by the Hydronics Institute Division of AHRI and listed in the AHRI Certification Directory.. 2.2 [2.2.1 BURNERS AND CONTROL EQUIPMENT Atmospheric-Type Gas Burner
Atmospheric-type gas burner (under 400,000 BTU/hr input). ANSI Z21.13/CSA 4.9. Automatic recycling burner. ON-OFF type combustion control system. [Interrupted] [Intermittent] pilot type ignition system, and pilot shall be electrode-ignited natural gas type. Design burner and combustion control equipment for firing natural gas having a specific gravity of [0.6] [_____] and a heating value of approximately [1000 BTU per cubic foot] and be an integral part of the boiler. Burner controls and safety equipment shall conform to applicable requirements of ANSI Z21.13/CSA 4.9, including complete gas shut-off and pilot gas. Gas pressure available: [_____ inches of water gage] [_____] psig.The boilers shall be constructed with a heavy gauge steel jacket assembly, primed and pre-painted on both sides. The combustion chamber shall be sealed and completely enclosed, independent of the outer jacket assembly, so that integrity of the outer jacket does not affect a proper seal. A burner/flame observation port shall be provided. The burner shall be a premix design and constructed of high temperature stainless steel with a woven metal fiber outer covering to provide modulating firing rates. The boilers shall be supplied with a gas valve designed with negative pressure regulation and be equipped with a variable speed blower system, to precisely control the fuel/air mixture to provide modulating boiler firing rates for maximum efficiency. The boilers shall operate in a safe condition at a derated output with gas supply pressures as low as 4 inches of water column. The Firing Control System shall be Direct Spark Ignition with Electronic Supervision ][2.2.2 Gas-Fired Power Burner
Gas-fired power burner (over 400,000 BTU/hr input). FS F-B-2910. Interrupted pilot type ignition system, and pilot shall be the electrode-ignited natural gas type. Design burner and combustion control equipment for firing natural gas having a specific gravity of [0.6] [_____] and a heating value of approximately [1000 BTU per cubic foot] [_____] and be an integral part of the boiler. Burner controls and safety equipment shall conform to applicable requirements of FS F-B-2910. Mount controls; including operating switches, indicating lights, gages, alarms, motor starters, fuses, and circuit elements of control systems on a single control panel or cabinet designed for separate mounting not on the burner in accordance with FS F-B-2910. The combustion control system shall be the [on/off] [high-low-off] [positioning] [metering] type. Locate flame scanner such that testing and cleaning of scanner can be accomplished without disassembly of burner. Provide fuel train as indicated. Gas pressure available: [_____ inches of water gage] [_____ psig].
SECTION 23 52 43.00 20
Page 5
123044
][2.2.3
Oil-Fired Power Burner
Oil-fired power burner (under 400,000 BTU/hr input). FS F-B-2909. Direct electric-spark-ignited type ignition system. Burner controls and safety equipment shall conform to applicable requirements of FS F-B-2909. The combustion control system shall be the [on/off] [high-low-off] [positioning] [metering] type. ][2.2.4 Oil-Fired Power Burner
Oil-fired power burner (over 400,000 BTU/hr input). FS F-B-2910. Pressure-atomizing type burner. Direct electric-spark-ignited type ignition system. Design burner and combustion control equipment for firing commercial grade number 2 fuel oil and be an integral part of the boiler. Burner controls and safety equipment shall conform to applicable requirements of FS F-B-2910. The combustion control system shall be the [on/off] [high-low-off] [positioning] [metering] type. Mount controls; including operating switches, indicating lights, gages, alarms, motor starters, fuses, and circuit elements of control systems on a single control panel or cabinet designed for separate mounting not on the burner in accordance with FS F-B-2910. Locate flame scanner such that testing and cleaning of scanner can be accomplished without disassembly of burner. Provide fuel train as indicated. ][2.2.5 Gas and Light Oil-Fired Power Burner
Gas and light oil-fired power burner (over 400,000 BTU/hr Input). FS F-B-2910. The combustion control system shall be the [on/off] [high-low-off] [positioning] [metering] type. Pressure-atomizing type oil burner. Interrupted-pilot type ignition system, and pilot be electrode-ignited natural gas type, except that the oil burner be direct electric-spark-ignited. Design burner and combustion control equipment for firing commercial grade number 2 fuel oil and natural gas having a specific gravity of [0.6] [_____] and a heating value of approximately [1000 BTU per cubic foot] [_____] and be an integral part of boiler. Burner controls and safety equipment shall conform to applicable requirements of FS F-B-2910. Mount controls; including operating switches, indicating lights, gages, alarms, motor starters, fuses, and circuit elements of control systems on a single control panel or cabinet designed for separate mounting not on the burner in accordance with FS F-B-2910. Locate flame scanner such that testing and cleaning of scanner can be accomplished without disassembly of burner. Provide fuel train as indicated. Gas pressure available: [_____ inches of water gage] [_____ psig]. ]2.3 BOILER TRIM AND CONTROL EQUIPMENT
Provide in accordance with MIL-B-18897 [and FS F-B-2910] and additional requirements specified below. 2.3.1 Emergency Disconnect SwitchShutdown Pushbutton
Provide and locate on wall outside boiler room entrance or just inside door, when boiler room door is on building exterior to allow rapid and complete shutdown of the boiler in the event of an emergency. Emergency switch shall be a [_____]-amp. fuse-type safety switchmushroom head pushbutton station. SwitchStation shall be red and furnished with a label indicating function of switch.
SECTION 23 52 43.00 20
Page 6
123044
2.3.2
Relief Valves
Provide relieving capacity for the full output of boiler installed. Relief-valve piping shall conform to ASTM A53/A53M, schedule 40 steel pipe and be piped full-size [to a floor drain] [to 6 inches above floor]. 2.3.3 Pressure and Altitude Gage or Combination Pressure/Altitude Gage
MIL-B-18897. Provide one located on supply water piping and one on return water piping. 2.3.3 Thermometer
Provide thermometer with a scale equivalent to 1.5 times outlet water temperature. Provide one located on supply water piping and one on return water piping. 2.3.4 Drain Tapping
Provide drain valve and piping [to a floor drain] [to 6 inches above floor]. 2.3.6 2.3.6.1 Make-up Water Station Pressure Reducing Station
Provide a water pressure-reducing valve and relief valve, or a combination of the two in the makeup water line to the boiler to maintain a water pressure of [12 psig] [_____] in the hot water system. Provide a 3/4 inch globe valve by-pass around this valve. 2.3.6.2 Backflow Preventers Locate upstream of by-pass.
Section 22 00 00 PLUMBING, GENERAL PURPOSE. 2.3.5 Feedwater Treatment Feeder
Provide in accordance with FS F-F-2901, Type II - Shot-Type Feeder (manual, intermittent feed), Style A - for use with pressures up to 200 psig maximum. 2.3.8 Combustion Regulator
Provide adjustable temperature, thermostatic immersion type that shall limit boiler water temperature to a maximum of 250 degrees F. Control shall actuate burner through an electric relay system to maintain boiler water temperature within normal prescribed limits at loads within rated capacity of boiler. 2.3.9 Air Vent Valve
Provide with screwed connection, stainless steel disk, and stainless steel seats to vent entrapped air. 2.3.10 High Temperature Limit Switch
Provide immersible aquastat type with a temperature setting above that of the combustion regulator and below that of the lowest relief valve setting. Aquastat shall function to cause a safety shutdown by closing fuel valves[,] [and] shutting down burner equipment [, activating a red indicating light, and sounding an alarm] in the event that boiler water SECTION 23 52 43.00 20 Page 7
123044
temperature rises to the high temperature limit setting. A safety shutdown due to high temperature shall require manual reset before operation can resume and prevent recycling of burner equipment. 2.3.11 Low Water Pressure Control
Provide mercury switch type. Control shall have a main scale, adjusting screws at the top of the case, and have an internal or external bellows. Control shall be the type which will open an electric circuit on a drop in pressure below a set minimum. Control shall be set and installed to cause a safety shutdown by closing fuel valves[,] [and] shutting down burner equipment [, activating a red indicating light, and sounding an alarm] in the event that water pressure in the system drops below [12 psig] [_____]. A safety shutdown due to low water pressure shall require manual reset before operation can resume and prevent recycling of burner equipment. 2.3.12 Low Water Level Cutoff Switch
Provide float actuated type. Low water level cutoff shall cause a safety shutdown by closing fuel valves[,] [and] shutting down burner equipment [, activating a red indicating light, and sounding an alarm] in the event that water level drops below the lowest safe permissible water level established by the boiler manufacturer and ASME BPVC SEC IV. A safety shutdown due to low water shall require manual reset before operation can resume and prevent recycling of burner equipment. 2.3.6 Boiler Safety Control Circuits
Provide boiler safety control circuits, including control circuits for burner [and draft fan], shall be single-phase, two-wire one-side grounded, and not over 120 volts. Provide safety control switching in ungrounded conductors. Provide overcurrent protection. In addition to circuit grounds, ground metal parts which do not carry current to a grounding conductor. The boilers shall utilize a 24 VAC control circuit and components. The control system shall have an electronic display for boiler set-up, boiler status, and boiler diagnostics. All components shall be easily accessed and serviceable from the front and top of the jacket. The boilers shall be equipped with; a temperature/pressure gauge, high limit temperature control certified to UL353, ASME certified pressure relief valve, outlet water temperature sensor, return water temperature sensor, a UL 353 certified flue temperature sensor, outdoor air sensor, low water flow protection and built-in adjustable freeze protection. The boilers shall feature the "Smart System" control with a Multi-Colored Graphic LCD display with Navigation Dial and Soft Keys for, password security, three loop temperature setpoints with individual outdoor air reset curves, pump delay with adjustable freeze protection, pump exercise. The Boiler shall be capable of controlling a variable speed boiler pump to keep a constant Delta T at all modulation rates. The BOILER shall have the capability to accept a 0-10 VDC input connection for BMS control of modulation or setpoint, enable disable of the boiler, variable system pump signal and a 0-10VDC output of boiler modulation rate. The Boiler shall have a built-in "Cascade" with sequencing options for "lead lag" or "efficiency optimized" modulation logic, with both capable of rotation while maintaining modulation of up to eight boilers without utilization of an external controller. Supply voltage shall be 120 volt / 60 hertz / single phase.
SECTION 23 52 43.00 20
Page 8
123044
The boilers shall be equipped with two terminal strips for electrical connection. A low voltage connection board with 42 data points for safety and operating controls, i.e., Auxiliary Relay, Auxiliary Proving Switch, Alarm Contacts, Runtime Contacts, Manual Reset Low Water Cutoff, Flow Switch, High and Low Gas Pressure Switches, Tank Thermostat, Three Wall Thermostat/Zone Controls, System Supply Sensor, Outdoor Sensor, Building Management System Signal, Modbus Control Contacts and Cascade Control Circuit. A high voltage terminal strip shall be provided for supply voltage. The high voltage terminal strip plus integral relays are provided for independent pump control of the System pump, the Boiler pump and the Domestic Hot Water pump. 2.3.14 Indicating Lights
Provide indicating lights as follows. Each safety interlock requiring a manual reset shall have an individually-labeled indicating light. Non-recycling controls/interlocks shall have the reset located on control/interlock itself. Indicating lights shall have colors as follows in lieu of those required by FS F-B-2910: a. b. c. Amber: Green: Ignition on Main fuel safety shut-off valves open
Red (One for Each): Safety lockout, flame failure, low water pressure, low water level, and high temperature Draft]
[d. Blue: 2.3.15
Alarm Bell
Provide alarm bell not less than 4 inches in diameter, electrically operated, with a manual disconnect switch. Disconnect switch shall be type and wired so that switching off alarm following a safety shutdown will not prevent alarm from sounding again upon recurrence of a subsequent safety shutdown condition. 2.3.16 Post-Combustion Purge
Provide controls and wiring necessary to ensure operation of draft fan for a period of not less than 15 seconds or of sufficient duration to provide four complete air changes in the boiler combustion chamber (whichever is greater) following shutdown of burner upon satisfaction of heat demand. Upon completion of post-combustion purge period, draft fan shall automatically shutdown until next restart. 2.3.17 Draft
Comply with boiler manufacturer's recommendations. 2.3.7 Stack, Breeching, and Supports
[Provide boiler stack constructed of sheet steel having a thickness of not less than 0.0972 inches with welded joints. Insulate stack located inside the building with 1 1/2 inches of mineral wool conforming to applicable requirements of ASTM C592, Class II - for use up to 1200 degrees F. Insulation shall receive a finish coat of finishing cement not less than 3/4 inch thick, trowelled to a smooth finish. Provide stack supports, umbrella collar and cap, and flue transition piece. Stack diameter and SECTION 23 52 43.00 20 Page 9
123044
height shall be in accordance with manufacturer's recommendations and conform to NFPA 211.] [NFPA 211, [Type B - gas] [Type L - oil and gas/oil], prefabricated multi-wall type, flashed to the roof, and complete with rain cap. Stack diameter and height shall be in accordance with manufacturer's recommendations and conform to NFPA 211.]The boilers shall be installed and vented with a Direct Vent Sidewall system with a horizontal sidewall termination of both the vent and combustion air. The flue shall be PVC, CPVC or Stainless Steel sealed vent material terminating at the sidewall with the manufacturers specified vent termination. A separate pipe shall supply combustion air directly to the Boiler from the outside. The air inlet pipe may be PVC, CPVC, ABS, Galvanized, or Stainless Steel sealed pipe. The air inlet must terminate on the same sidewall with the manufacturer's specified air inlet cap. The boilers total combined air intake length shall not exceed 100 equivalent feet. The boilers total combined exhaust venting length shall not exceed 100 equivalent feet. Foam Core pipe is not an approved material for exhaust piping. The boilers shall have an independent laboratory rating for Oxides of Nitrogen (NOx) of 20 ppm or less corrected to 3% O2. The manufacturer shall verify proper operation of the burner, all controls and the heat exchanger by connection to water and venting for a factory fire test prior to shipping. The boilers shall operate at altitudes up to 4,500 feet above sea level without additional parts or adjustments. 2.3.19 Hot Water Coils
Provide coils capable of heating [_____] GPM of water with [_____] degreeF rise conforming to MIL-B-18897. 2.3.20 Stack Thermometer
Provide flue gas thermometer with scale calibrated from 150 to 750 degrees F and mounted in flue gas outlet. 2.4 ELECTRIC MOTORS
Electric motors shall meet requirements of NEMA MG 1. Motors less than 1 hp shall meet NEMA High Efficiency requirements. Motors 1 hp and larger shall meet NEMA Premium Efficiency requirements. Motors which are an integral part of the packaged boiler system shall be the highest efficiency available by the manufacturer of the packaged boiler. Motors shall be variable speed. PART 3 3.1 EXECUTION EQUIPMENT INSTALLATION
Install equipment in accordance with manufacturer's installation instructions. Grout equipment mounted on concrete foundations before installing piping. Install piping in such a manner as not to place a strain on equipment. Do not bolt flanged joints tight unless they match. Grade, anchor, guide, and support piping without low pockets. Feedwater treatment feeders shall be mounted so that the top of the feeder is no higher than 48 inches above the finished floor.
SECTION 23 52 43.00 20
Page 10
123044
3.2
EQUIPMENT FOUNDATIONS
Locate equipment foundations as indicated, designed, and made of sufficient size and weight to preclude shifting of equipment under operating conditions or under abnormal conditions that could be imposed upon the equipment. Foundations shall meet requirements of the equipment manufacturer. Concrete and grout shall conform to Section 03 30 00 CAST-IN-PLACE CONCRETE. 3.3 BOILER CLEANING
Before being placed in service, boiler shall be boiled out for a period of 24 hours at a pressure not exceeding 12 psig. Solution to be used in the boiler for the boiling out process shall consist of two pounds of trisodium phosphate per 100 gallons of water. Upon completion of boiling out, flush out boiler with potable water, drain, and charge with chemically treated water. Protect boiler and appurtenances against internal corrosion until testing is completed and boiler is accepted. Professional services are required for cleaning/treatment process. 3.4 FIELD QUALITY CONTROL
Perform and furnish everything required for inspections and tests as specified herein to demonstrate that boiler and auxiliary equipment, as installed, are in compliance with contract requirements. Start-up and operate the system. During this time, clean strainers until no further accumulation of foreign material occurs. Exercise care to minimize loss of water when strainers are cleaned. Adjust safety and automatic control instruments as necessary to place them in proper operation and sequence. Test instrumentation shall be calibrated and have full scale readings from 1.5 to 2 times test values. 3.4.1 Operational Tests
Operate each boiler and appurtenances prior to final testing and insure that necessary adjustments have been made. Provide testing equipment required to perform tests. During this testing period, provide operating instructions and training to persons tasked with operation of the boiler. T ests shall be accomplished with both fuels on dual fuel units and include the following: 3.4.1.1 Preliminary Operational Test
Operate the boilers continuously for a period of at least 8 hours to demonstrate proper operability of the combustion control, flame safeguard control, and safety interlocks. 3.4.1.2 Acceptance Operational Test and Inspection
Conduct a preliminary operational test prior to requesting an acceptance operational test and inspection by a [_____]Mid-Atlantic Division, Naval Facilities Engineering Command Boiler inspector. The Contracting Officer, upon receipt of the notice from the Contractor, shall request the boiler be inspected by [_____]Mid-Atlantic Division Naval Facilities Engineering Command. Fifteen days advance notice is required for scheduling inspector to conduct acceptance operational test and inspection.
SECTION 23 52 43.00 20
Page 11
123044
3.5
WASTE MANAGEMENT
Separate waste in accordance with the Waste Management Plan. Close and seal tightly all partly used adhesives and solvents; store protected in a well-ventilated, fire-safe area at moderate temperature.
SECTION 23 52 43.00 20
Page 12
123044
SECTION 23 64 10 WATER CHILLERS, VAPOR COMPRESSION TYPE 08/08 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. AIR-CONDITIONING, HEATING AND REFRIGERATION INSTITUTE (AHRI) AHRI 550/590 (2003) Performance Rating of Water-Chilling Packages Using the Vapor Compression Cycle (2008) Method of Measuring Machinery Sound Within an Equipment Space AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA) ABMA 11 (1990) Load Ratings and Fatigue Life for Roller Bearings (1990; R 2008) Load Ratings and Fatigue Life for Ball Bearings AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE) ANSI/ASHRAE 15 & 34 (2010; Addenda a, b, c, d, e, f, g, h, and i) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants
AHRI 575
ABMA 9
AMERICAN WELDING SOCIETY (AWS) AWS Z49.1 (2005) Safety in Welding and Cutting and Allied Processes
ASTM INTERNATIONAL (ASTM) ASTM A307 (2010) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength (2009) Standing Practice for Operating Salt Spray (Fog) Apparatus (2000; R 2011) Zinc Dust Pigment (2011a) Standard Test Method for Surface Burning Characteristics of Building Materials SECTION 23 64 10 Page 1
ASTM B117
ASTM D 520 ASTM E 84
123044
ASTM F 104
(2011) Standard Classification System for Nonmetallic Gasket Materials
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA MG 11 (1977; R 2007) Energy Management Guide for Selection and Use of Single Phase Motors
1.2
SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for [Contractor Quality Control approval.] [information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] The following shall be submitted in accordance with Section 01 33 00.05 20 CONSTRUCTION SUBMITTAL PROCEDURES: SD-03 Product Data Water Chiller[; G][; G, [_____]] Manufacturer's standard catalog data, at least highlighted to show material, size, options, performance charts and curves, etc. in adequate detail to demonstrate compliance with contract requirements. Data shall include manufacturer's recommended installation instructions and procedures. Data shall be adequate to demonstrate compliance with contract requirements as specified within the paragraphs: a. b. c. Water Chiller Chiller Components Accessories
If vibration isolation is specified for a unit, vibration isolator literature shall be included containing catalog cuts and certification that the isolation characteristics of the isolators provided meet the manufacturer's recommendations. [Posted Instructions Posted instructions, including equipment layout, wiring and control diagrams, piping, valves and control sequences, and typed condensed operation instructions. The condensed operation instructions shall include preventative maintenance procedures, methods of checking the system for normal and safe operation, and procedures for safely starting and stopping the system. The posted instructions shall be framed under glass or laminated plastic and be posted where indicated by the Contracting Officer.] Verification of Dimensions A letter including the date the site was visited, conformation of existing conditions, and any discrepancies found. Manufacturer's Multi-Year Compressor Warranty
SECTION 23 64 10
Page 2
123044
Manufacturer's multi-year warranty for compressor(s) in air-cooled water chillers as specified. Factory Tests Schedules which identify the date, time, and location for each test. Schedules shall be submitted for both the Chiller Performance Test and the Chiller Sound Test. [The Chiller Performance Test schedule shall also allow the witnessing of the test by a Government Representative.] System Performance Tests A schedule, at least [2] [_____] weeks prior to the start of related testing, for the system performance tests. The schedules shall identify the proposed date, time, and location for each test. Demonstrations A schedule, at least [2] [_____] weeks prior to the date of the proposed training course, which identifies the date, time, and location for the training. Water Chiller - field acceptance test plan SD-06 Test Reports Field Acceptance Testing Water Chiller - field acceptance test report Factory Tests [Six] [_____] copies of the report shall be provided in bound 8 1/2 by 11 inch booklets. Reports shall certify the compliance with performance requirements and follow the format of the required testing standard for both the Chiller Performance Tests and the Chiller Sound Tests. Test report shall include certified calibration report of all test instrumentation. Calibration report shall include certification that all test instrumentation has been calibrated within 6 months prior to the test date, identification of all instrumentation, and certification that all instrumentation complies with requirements of the test standard. Test report shall be submitted [1] [_____] week after completion of the factory test. System Performance Tests [Six] [_____] copies of the report shall be provided in bound 8 1/2 by 11 inch booklets. SD-07 Certificates Refrigeration System[; G][; G, [_____]] Where the system, components, or equipment are specified to comply with requirements of AGA, NFPA, ARI, ASHRAE, ASME, or UL, [1 ] [_____] copy of proof of such compliance shall be provided. The label or listing of the specified agency shall be acceptable SECTION 23 64 10 Page 3
123044
evidence. In lieu of the label or listing, a written certificate from an approved, nationally recognized testing organization equipped to perform such services, stating that the items have been tested and conform to the requirements and testing methods of the specified agency may be submitted. When performance requirements of this project's drawings and specifications vary from standard ARI rating conditions, computer printouts, catalog, or other application data certified by ARI or a nationally recognized laboratory as described above shall be included. If ARI does not have a current certification program that encompasses such application data, the manufacturer may self certify that his application data complies with project performance requirements in accordance with the specified test standards. SD-08 Manufacturer's Instructions Water Chiller - Installation Instruction[; G][; G, [_____]] SD-10 Operation and Maintenance Data Operation and Maintenance Manuals[; G][; G, [_____]] [Six] [_____] complete copies of an operation manual in bound 8 1/2 by 11 inch booklets listing step-by-step procedures required for system startup, operation, abnormal shutdown, emergency shutdown, and normal shutdown at least [4] [_____] weeks prior to the first training course. The booklets shall include the manufacturer's name, model number, and parts list. The manuals shall include the manufacturer's name, model number, service manual, and a brief description of all equipment and their basic operating features. [Six] [_____] complete copies of maintenance manual in bound 8 1/2 by 11 inch booklets listing routine maintenance procedures, possible breakdowns and repairs, and a trouble shooting guide. The manuals shall include piping and equipment layouts and simplified wiring and control diagrams of the system as installed. 1.3 SAFETY REQUIREMENTS
Exposed moving parts, parts that produce high operating temperature, parts which may be electrically energized, and parts that may be a hazard to operating personnel shall be insulated, fully enclosed, guarded, or fitted with other types of safety devices. Safety devices shall be installed so that proper operation of equipment is not impaired. Welding and cutting safety requirements shall be in accordance with AWS Z49.1. 1.4 DELIVERY, STORAGE, AND HANDLING
Stored items shall be protected from the weather, humidity and temperature variations, dirt and dust, or other contaminants. Proper protection and care of all material both before and during installation shall be the Contractor's responsibility. Any materials found to be damaged shall be replaced at the Contractor's expense. During installation, piping and similar openings shall be capped to keep out dirt and other foreign matter.
SECTION 23 64 10
Page 4
123044
1.5 1.5.1
PROJECT REQUIREMENTS Verification of Dimensions
The Contractor shall become familiar with all details of the work, verify all dimensions in the field, and advise the Contracting Officer of any discrepancy before performing any work. 1.6 Warranty
In addition to the warranty requirements specification in Division 00, Contract Requirements, the following major components of the chiller shall be covered by a warranty of a duration period of five years: compressor, and [_____].. 1.7 MANUFACTURER'S MULTI-YEAR COMPRESSOR WARRANTY
The Contractor shall provide a [5] [10] year [parts only (excludes refrigerant)][parts and labor (includes refrigerant)] manufacturer's warranty on the chiller compressor(s). This warranty shall be directly from the chiller manufacturer to the Government and shall be in addition to the standard one-year warranty of construction. The manufacturer's warranty shall provide for the repair or replacement of the chiller compressor(s) that become inoperative as a result of defects in material or workmanship within [5] [10] years after the date of final acceptance. When the manufacturer determines that a compressor requires replacement, the manufacturer shall furnish new compressor(s) at no additional cost to the Government. Upon notification that a chiller compressor has failed under the terms of the warranty, the manufacturer shall respond in no more than [6 ] [24] [_____] hours. Response shall mean having a manufacturer-qualified technician onsite to evaluate the extent of the needed repairs. The warranty period shall begin on the same date as final acceptance and shall continue for the full product warranty period. 1.7.1 Indexed Notebook
The Contractor shall furnish to the Contracting Officer a bound and indexed notebook containing a complete listing of all water chillers covered by a manufacturer's multi-year warranty. The chiller list shall state the duration of the warranty thereof, start date of the warranty, ending date of the warranty, location of the warranted equipment, and the point of contact for fulfillment of the warranty. This information shall be provided for each chiller and the recorded chiller serial numbers shall identify each chiller. Point of contact shall include the name of the service representative along with the day, night, weekend, and holiday phone numbers for a service call. The completed bound and indexed notebook shall be delivered to the Contracting Office prior to final acceptance of the facility.The Contractor shall furnish with each manufacturer's multi-year warranty the name, address, and telephone number (day, night, weekend, and holiday) of the service representative nearest to the location where the equipment is installed. Upon a request for service under the multi-year warranty, the service representative shall honor the warranty during the warranty period, and shall provide the services prescribed by the terms of the warranty. 1.7.2 Equipment Warranty Tags
At the time of installation, each item of manufacturer's multi-year warranted equipment shall be tagged with a durable, oil- and SECTION 23 64 10 Page 5
123044
water-resistant tag, suitable for interior and exterior locations, resistant to solvents, abrasion, and fading due to sunlight. The tag shall be attached with copper wire or a permanent, pressure-sensitive, adhesive backing. The tag shall be installed in an easily noticed location attached to the warranted equipment. The tag for this equipment shall be similar to the following in format, and shall contain all of the listed information: MANUFACTURER'S MULTI-YEAR WARRANTY EQUIPMENT TAG Equipment/Product Covered: ____________________ Manufacturer:_______Model No.:_____Serial No.:__ Warranty Period: From _________to _____________ Contract No.: _________________________________ Warranty Contact: _____________________________ Name: _________________________________________ Address: ______________________________________ Telephone: ____________________________________ STATION PERSONNEL SHALL PERFORM PREVENTIVE MAINTENANCE AND OPERATIONAL MAINTENANCE PART 2 2.1 PRODUCTS STANDARD COMMERCIAL PRODUCTS
Materials and equipment shall be standard Commercial cataloged products of a manufacturer regularly engaged in the manufacturing of such products, which are of a similar material, design and workmanship. These products shall have a two year record of satisfactory field service prior to bid opening. the two year record of service shall include applications of equipment and materials under similar circumstances and of similar size. Products having less than a two year record of satisfactory field service shall be acceptable if a certified record of satisfactory field service for not less than 6000 hours can be shown. The 6000 hour service record shall not include any manufacturer's prototype or factory testing. Satisfactory field service shall have been completed by a product that has been, and presently is being sold or offered for sale on the commercial market through the following copyrighted means: advertisements, manufacturer's catalogs, or brochures. 2.2 MANUFACTURER'S STANDARD NAMEPLATES
[Major equipment including chillers, compressors, compressor drivers, condensers, water coolers, receivers, refrigerant leak detectors, heat exchanges, fans, and motors shall have the manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to the item of equipment. Plates shall be durable and legible throughout equipment life. Plates shall be fixed in prominent locations with nonferrous screws or bolts.] [Nameplates are required on major components if the manufacturer needs to provide specific engineering and manufacturing information pertaining to the particular component. Should replacement of this component be required, nameplate information will insure correct operation of the unit after replacement of this component.]
SECTION 23 64 10
Page 6
123044
2.3
ELECTRICAL WORK a. Provide motors, controllers, integral disconnects, contactors, and controls with their respective pieces of equipment, except controllers indicated as part of motor control centers. Provide electrical equipment, including motors and wiring, as specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Manual or automatic control and protective or signal devices required for controls and devices specified, but not shown, shall be provided. For packaged equipment, the manufacturer shall provide controllers including the required monitors and timed restart. b. Provide phase monitors with automatic reset upon fault correction to monitor the following: phase unbalance protection over/under voltage protection phase loss protection delay of break tumer to delay automatic restarts non critical fault delay programmable auto/manual restart load and line side monitoring
bc. For single-phase motors, provide high-efficiency type, fractional-horsepower alternating-current motors, including motors that are part of a system, in accordance with NEMA MG 11. cd. For polyphase motors, provide squirrel-cage medium induction motors, including motors that are part of a system, and that meet the efficiency ratings for premium efficiency motors in accordance with NEMA MG 11. de. Provide motors in accordance with NEMA MG 11 and of sufficient size to drive the load at the specified capacity without exceeding the nameplate rating of the motor. Motors shall be rated for continuous duty with the enclosure specified. Motor duty requirements shall allow for maximum frequency start-stop operation and minimum encountered interval between start and stop. Motor torque shall be capable of accelerating the connected load within 20 seconds with 80 percent of the rated voltage maintained at motor terminals during one starting period. Provide motor starters complete with thermal overload protection and other necessary appurtenances. [Motor bearings shall be fitted with grease supply fittings and grease relief to outside of the enclosure.] ef. Provide inverter duty premium efficiency motors for use with variable frequency drives. fg. [Where two-speed or variable-speed motors are indicated, solid-state variable-speed controllers may be provided to accomplish the same function. Use solid-state variable-speed controllers for motors rated 10 hp or less and variable frequency drives for larger motors.] [Provide variable frequency drives for motors as specified in Section 26 29 23 VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600 VOLTS] 2.4 SELF-CONTAINED WATER CHILLERS, VAPOR COMPRESSION TYPE
Unless necessary for delivery purposes, units shall be assembled, leak-tested, charged (refrigerant and oil), and adjusted at the factory. SECTION 23 64 10 Page 7
123044
In lieu of delivery constraints, a chiller may be assembled, leak-tested, charged (refrigerant and oil), and adjusted at the job site by a factory representative. Unit components delivered separately shall be sealed and charged with a nitrogen holding charge. Parts weighing 50 pounds or more which must be removed for inspection, cleaning, or repair, such as motors, gear boxes, cylinder heads, casing tops, condenser, and cooler heads, shall have lifting eyes or lugs. Chiller shall be provided with a single point wiring connection for incoming power supply. Chiller's condenser and water cooler shall be provided with [standard] [marine] water boxes with [grooved mechanical] or [flanged] [welded] connections. 2.4.1 ScrollRotary Screw, Controlled with Variable Frequency Drive, Reciprocating, or Rotary Screw Type Chiller shall be rated in accordance with AHRI 550/590. Chiller shall conform to ANSI/ASHRAE 15 & 34. As a minimum, chiller shall include the following components as defined in paragraph CHILLER COMPONENTS. a. b. c. d. e. Refrigerant and oil Structural base Chiller refrigerant circuit Controls package ScrollRotary Screw, controlled by variable frequency drive, reciprocating, or rotary screw compressor Compressor driver, [electric motor] [gas-engine] Compressor driver connection Water cooler (evaporator) [Air][Water]-cooled condenser coil [Heat recovery condenser] [Receiver] [Tools] Centrifugal or Rotary Screw Type
f. g. h. i. j. k. l. 2.4.2
Chiller shall be constructed and rated in accordance with AHRI 550/590. Chiller shall conform to ANSI/ASHRAE 15 & 34. As a minimum, chiller shall include the following components as defined in paragraph CHILLER COMPONENTS. a. b. c. d. e. Refrigerant and oil Structural base Chiller refrigerant circuit Controls package Centrifugal or rotary screw compressor
SECTION 23 64 10
Page 8
123044
f. g. h. i. j. k. l. m. 2.5
Compressor driver, [electric motor] [gas-engine] [steam turbine] Compressor driver connection Water cooler (evaporator) [Air][Water]-cooled condenser coil [Heat recovery condenser coil] [Receiver] Purge system for chillers which operate below atmospheric pressure [Tools] SPLIT-SYSTEM WATER CHILLER, VAPOR COMPRESSION TYPE
Total chiller system shall be constructed and rated in accordance with ARI 550/590. Individual chiller components shall be constructed and rated in accordance with the applicable ARI standards. Chiller system shall be conform to ANSI/ASHRAE 15 & 34. [The chiller shall be ASHRAE 90.1 - IP complaint and 10 CFR Part 433, 434 and 435 efficiency performance standards for federal construction. The manufacturer shall provide certification of compliance]. Chiller shall be assembled, leak-tested, charged (refrigerant and oil), and adjusted at the job site in strict accordance with manufacturer's recommendations. Unit components delivered separately shall be sealed and charged with a nitrogen holding charge. Unit assembly shall be completed in strict accordance with manufacturer's recommendations. Chiller shall operate within capacity range and speed recommended by the manufacturer. Parts weighing 50 pounds or more which must be removed for inspection, cleaning, or repair, shall have lifting eyes or lugs. Chiller shall include all customary auxiliaries deemed necessary by the manufacturer for safe, controlled, automatic operation of the equipment. Chiller's condenser and water cooler shall be provided with [standard] [marine] water boxes with [grooved mechanical] [flanged] [welded] connections. Chillers shall operate at partial load conditions without increased vibration over normal vibration at full load, and shall be capable of continuous operation down to minimum capacity. As a minimum, chiller shall include the following components as defined in paragraph CHILLER COMPONENTS. a. b. c. d. e. f. 2.5.1 Refrigerant and oil Structural base Chiller refrigerant circuit Controls package [Receiver] [Tools] Compressor-Chiller Unit
As a minimum, the compressor-chiller unit shall include the following components as defined in paragraph CHILLER COMPONENTS.
SECTION 23 64 10
Page 9
123044
a. b. c. d. 2.5.2
Scroll, reciprocating, or rotary screw compressor Compressor driver, electric motor Compressor driver connection Water cooler (evaporator) Condensing Unit
As a minimum, the condensing unit shall include the following components as defined in paragraph CHILLER COMPONENTS. a. b. c. d. 2.5.3 2.5.3.1 Scroll, reciprocating, or rotary screw compressor Compressor driver, electric motor Compressor driver connection Air or water cooled condenser Remote Water Cooler (Evaporator) Shell and Tube Type
Cooler shall be constructed and rated in accordance with AHRI 480. Cooler shall be of the shell-and-coil or shell-and-tube type design. Cooler's refrigerant side shall be designed and factory pressure tested to comply with ANSI/ASHRAE 15 & 34. Cooler's water side shall be designed and factory pressure tested for not less than [150] [250] psi. Cooler shell shall be constructed of seamless or welded steel. [Coil bundles shall be totally removable and arranged to drain completely.] Tubes shall be seamless copper, plain, integrally finned with smooth bore or integrally finned with enhanced bore. Each tube shall be individually replaceable. Tubes shall be installed into carbon mild steel tube sheets by rolling. Tube baffles shall be properly spaced to provide adequate tube support and cross flow. Cooler shall be skid-mounted. Refrigerant circuit shall be complete with liquid solenoid valve and expansion device capable of modulating to the minimum step of capacity unloading. For the water side of water cooler, performance shall be based on a water velocity not less than 3 fps and not more than 12 fps and a fouling factor of 0.00025. [Evaporator shall be provided with electric freeze protection type.] 2.5.3.2 Brazed Plate Type
Cooler shall be constructed and rated in accordance with AHRI 480. Cooler shall be of the brazed plate design. Cooler's refrigerant side shall be designed and factory pressure tested to comply with ANSI/ASHRAE 15 & 34. Cooler's water side shall be designed and factory pressure tested for not less than [150] [250] psi. Cooler shell shall be constructed of stainless steel plates brazed together with copper. Refrigerant circuit shall be complete with liquid solenoid valve and expansion device capable of modulating to the minimum step of capacity unloading. For the water side of water cooler, performance shall be based on a water velocity not less than 3 fps and not more than 12 fps and a fouling factor of 0.00025. [Evaporator shall be provided with electric freeze protection type.]
SECTION 23 64 10
Page 10
123044
2.5.4
Remote Air-Cooled Condenser
Condenser shall be a factory-fabricated and assembled unit, consisting of coils, fans, and condenser fan motors. Condenser shall be constructed and rated in accordance with ANSI/AHRI 460. [Unless the condenser coil is completely protected through inherent design, louvered panel coil guards shall be provided by the manufacturer to prevent physical damage to the coil.] Manufacturer shall certify that the condenser and associated equipment are designed for the submitted condensing temperature. For design conditions, if matched combination catalog ratings matching remote condensers to compressors are not available, the Contractor shall furnish a crossplotting of the gross heat rejection of the condenser against the gross heat rejection of the compressor, for the design conditions to show the compatibility of the equipment furnished. 2.5.4.1 Condenser Casing
Condenser casing shall be aluminum not less than [0.040] [0.080] inch or hot-dip galvanized steel not lighter than 18 gauge. Condensers having horizontal air discharge shall be provided with discharge baffle to direct air upward, constructed of the same material and thickness as the casing. 2.5.4.2 Coil
Condenser coil shall be of the extended-surface fin-and-tube type and shall be constructed of seamless [copper] [or] [aluminum] tubes with compatible [copper] [or] [aluminum] fins. Fins shall be soldered or mechanically bonded to the tubes and installed in a metal casing. Coils shall be circuited and sized for a minimum of 5 degrees F subcooling and full pumpdown capacity. Coil shall be factory leak and pressure tested after assembly in accordance with ANSI/ASHRAE 15 & 34. [Coil shall be entirely coated with the manufacturer's standard epoxy or vinyl coating.] 2.5.4.3 Fans
Fans shall be centrifugal or propeller type as best suited for the application. Fans shall be direct or V-belt driven. [Belt drives shall be completely enclosed within the unit casing or equipped with a guard.] [When belt drive is provided, an adjustable sheave to furnish not less than 20 percent fan-speed adjustment shall be provided. Sheaves shall be selected to provide the capacity indicated at the approximate midpoint of the adjustment.] Fans shall be statically and dynamically balanced. 2.5.4.4 Condenser Sizing
Size condensers for full capacity at 30 degrees F temperature difference between entering outside air and condensing refrigerant. Subcooling shall not be considered in determining compressor and condenser capacities. For design conditions, submit a cross-plot of net refrigeration effect of compressor to establish net refrigeration effect and compatibility of equipment furnished. 2.5.4.5 Low Ambient Control
Provide factory mounted head pressure control for operation during low ambient conditions. Head pressure shall be controlled by [fan cycling,] [fan speed control,] [condenser refrigerant flooding]. Low ambient control shall permit compressor operation below [ 40 degrees F] [ 0 degrees F] [ [_____] degrees F]. SECTION 23 64 10 Page 11
123044
2.5.4.6
High Ambient Unloading
Provide unloading capability to allow operation in high ambient conditions [ [_____] degrees F] above design conditions. 2.5.5 Remote Water-Cooled Condenser
Condenser shall be a factory-fabricated and assembled unit constructed and rated in accordance with AHRI 450. Condenser shall be of the shell-and-coil or shell-and-tube type design. Condenser's refrigerant side shall be designed and factory pressure tested to comply with ANSI/ASHRAE 15 & 34. Condenser's water side shall be designed and factory pressure tested for not less than [150] [250] psi. Condensers shall be complete with pressure relief valve or rupture disk, water drain connections, refrigerant charging valve, refrigerant valves, liquid-level indicating devices, and stand or saddle. Low pressure refrigerant condenser shall be provided with a purge valve located at the highest point in the condenser to purge non-condensibles trapped in the condenser. Condenser shell shall be constructed of seamless or welded steel. [Coil bundles shall be totally removable and arranged to drain completely.] Tubes shall be seamless copper, plain, integrally finned with smooth bore or integrally finned with enhanced bore. Each tube shall be individually replaceable, except for the coaxial tubes. Tubes shall be installed into carbon mild steel tube sheets by rolling. Tube baffles shall be properly spaced to provide adequate tube support and cross flow. Condenser performance shall be based on water velocities not less than 3 fps nor more than 12 fps and a fouling factor of [0.00025] [0.0005]. Water-cooled condensers may be used for refrigerant storage in lieu of a separate liquid receiver, if the condenser storage capacity is 20 percent in excess of the fully charged system for remote water cooled condensers. As a minimum, the condenser shall include the following components as defined in paragraph "Chiller Components". a. b. Liquid-level indicating devices. Companion flanges, bolts, and gaskets for flanged water connections.
2.5.6
Remote Evaporatively-Cooled Condenser
Condenser shall be rated and tested in accordance with the requirements of ASHRAE 64. Condenser shall include fans, water pump with suction strainer, electric motor and drive equipment, water eliminators if required, condensing coil, liquid receiver if required, water pan or sump, spray nozzles or water-distribution pan, water strainer, water make-up assembly, bleeder with flow valve of the needle valve type sized for the flow required or a fixed orifice, enclosure with suitable access doors, and air-inlet and outlet openings. No water shall carry over into the unit discharge outlet. 2.5.6.1 Condenser Casing
Enclosure shall be constructed of not lighter than [18 gauge hot-dip galvanized steel] [0.080 inch aluminum], reinforced and braced. Access doors or panels suitably sized and located shall be provided for access to water nozzles or distribution pan, coils, and valves for cleaning, repair, or removal of the item. Access doors or panels shall be gasketed with synthetic rubber, or equivalent gasket material, and locked in place with SECTION 23 64 10 Page 12
123044
thumb screws or catches. One-half inch mesh hot-dip galvanized steel or copper air-inlet screens shall be provided on each air inlet. 2.5.6.2 Refrigerant Section
Condenser coil shall be constructed of unfinned copper or steel tubes hot-dip galvanized after fabrication. The receiver shall be welded steel and shall be fitted and tested in accordance with ANSI/AHRI 495. A refrigerant charging valve shall be installed in the liquid line between the receiver cut-off valve and the expansion device. Refrigerant section shall be tested in accordance with ASHRAE 15 for the refrigerant employed in the system. 2.5.6.3 Fans
Fans shall be centrifugal or propeller type as best suited for the application. Fans shall be direct or V-belt driven. Belt drives shall be completely enclosed within the unit casing or equipped with a guard. When belt drive is provided, an adjustable sheave to furnish not less than 20 percent fan-speed adjustment shall be provided. Sheaves shall be selected to provide the capacity indicated at the approximate midpoint of the adjustment. Fans shall be statically and dynamically balanced. Fan motor shall be totally enclosed type or open dripproof and located within an enclosure to be fully protected from the weather. 2.5.6.4 Water Section
Water eliminators shall be constructed of nonferrous metal, of an approved nonmetallic material, or of not lighter than 24 gauge steel, hot-dip galvanized after fabrication. Spray nozzles shall be brass nonclogging type designed to permit easy disassembly, and shall be arranged for easy access. Water pump shall be bronze-fitted centrifugal or turbine type, and may be mounted as an integral part of the evaporative condenser or remotely on a separate mounting pad. Pump suction shall be fully submerged and provided with screened inlet. Water pan or sump shall be constructed of not lighter than 14 gauge steel, hot-dip galvanized after fabrication, or molded acid-resistant glass-fiber-reinforced polyester. Water distribution pan shall be constructed of not lighter than 16 gauge steel, hot-dip galvanized after fabrication. Joints shall be watertight. Water pan or sump shall be provided with drain, overflow, and make-up water connection with stop valve and float valve. A bleed line with a flow valve of the needle type sized for the flow required or fixed orifice shall be provided in the pump discharge line and shall be extended to the nearest drain for continuous discharge. 2.5 2.5.1 CHILLER COMPONENTS Refrigerant and Oil
Refrigerants shall be one of the fluorocarbon gases. Refrigerants shall have number designations and safety classifications in accordance with ANSI/ASHRAE 15 & 34. [Refrigerants shall have an Ozone Depletion Potential (ODP) of 0.055 or less.] [Refrigerants classified by the EPA as Class 2 shall not be allowed with the exception of R-123.] [The ODP shall be in accordance with the "Montreal Protocol On Substances That Deplete The Ozone Layer," September 1987, as amended through 2000, sponsored by the United Nations Environment Programme.] Do not use 400 series refrigerants except 407C and 410A. If sufficient competition is available with 410A, the use of 407C is prohibited. SECTION 23 64 10 Page 13
123044
2.5.2
Structural Base
Chiller and individual chiller components shall be provided with a factory-mounted structural steel base (welded or bolted) or support legs. Chiller and individual chiller components shall be isolated from the building structure by means of [molded neoprene isolation pads.] [vibration isolators with published load ratings. Vibration isolators shall have isolation characteristics as recommended by the manufacturer for the unit supplied and the service intended.] 2.5.3 Chiller Refrigerant Circuit
Chiller refrigerant circuit shall be completely piped and factory leak tested. For multicompressor units, not less than 2 independent refrigerant circuits shall be provided. Circuit shall include as a minimum a [ combination filter and drier,] combination sight glass and moisture indicator, liquid-line solenoid valve for reciprocating, an electronic or thermostatic expansion valve with external equalizer, charging ports, compressor service valves for field-serviceable compressors, and superheat adjustment. 2.5.4 Controls Package
Chiller shall be provided with a complete [factory-mounted] [remote-mounted where indicated], prewired electric or microprocessor based operating and safety control system. Controls package shall contain as a minimum a digital display or acceptable gauges, an on-auto-off switch, [motor starters, variable frequency drive,] [disconnect switches,] power wiring, and control wiring. Controls package shall provide operating controls, monitoring capabilities, programmable setpoints, safety controls, and EMCS interfaces as defined below. 2.5.4.1 Operating Controls
Chiller shall be provided with the following adjustable operating controls as a minimum. a. b. Leaving chilled water temperature control Adjustable timer or automated controls to prevent a compressor from short cycling Automatic lead/lag controls (adjustable) for multi-compressor units Load limiting System capacity control to adjust the unit capacity in accordance with the system load and the programmable setpoints. Controls shall automatically re-cycle the chiller on power interruption. Startup and head pressure controls to allow system operation at all ambient temperatures down to [_____]0 degrees F [Fan sequencing for air-cooled condenser] Monitoring Capabilities
c. d. e.
f.
g.
2.5.4.2
During normal operations, the control system shall be capable of monitoring SECTION 23 64 10 Page 14
123044
and displaying the following operating parameters. Access and operation of display shall not require opening or removing any panels or doors. a. b. c. d. e. f. g. h. i. j. Entering and leaving chilled water temperatures Self diagnostic Operation status Operating hours Number of starts Compressor status and motor speed (hz) (on or off) Refrigerant discharge and suction pressures Oil pressure [Condenser water entering and leaving temperatures] [Number of purge cycles over the last 7 days] Programmable Setpoints
2.5.4.3
The control system shall be capable of being reprogrammed directly at the unit. [No parameters shall be capable of being changed without first entering a security access code.] The programmable setpoints shall include the following as a minimum. a. b. cb. 2.5.4.4 Leaving Chilled Water Temperature [Leaving Condenser Water Temperature] [Time Clock/Calendar Date] Safety Controls with Manual Reset
Chiller shall be provided with the following safety controls which automatically shutdown the chiller and which require manual reset. a. b. bc. cd. de. ef. fg. 2.5.4.5 Low chilled water temperature protection High condenser refrigerant discharge pressure protection Low evaporator pressure protection Chilled water flow detection High motor winding temperature protection Low oil flow protection if applicable [Motor current overload and phase loss protection] Safety Controls with Automatic Reset
Chiller shall be provided with the following safety controls which automatically shutdown the chiller and which provide automatic reset. SECTION 23 64 10 Page 15
123044
a. b.
Over/under voltage protection Chilled water flow interlock
c.
[Phase reversal protection] Remote Alarm
2.5.4.6
During the initiation of a safety shutdown, a chiller's control system shall be capable of activating a remote alarm bell. In coordination with the chiller, the Contractor shall provide an alarm circuit (including transformer if applicable) and a minimum 4 inch diameter alarm bell. Alarm circuit shall activate bell in the event of machine shutdown due to the chiller's monitoring of safety controls. The alarm bell shall not sound for a chiller that uses low-pressure cutout as an operating control. 2.5.4.7 Energy Management Control System (EMCS) Interface
The control system shall be capable of communicating all data to a remote integrated DDC processor through a single shielded cable. The data shall include as a minimum all system operating conditions, capacity controls, and safety shutdown conditions. The control system shall also be capable of receiving at a minimum the following operating commands. a. b. c. 2.5.5 2.6.5.1 Remote Unit Start/Stop [Remote Chilled Water Reset] [Remote Condenser Water Reset] Compressor(s) Reciprocating Compressor(s)
Rotating parts shall be statically and dynamically balanced at the factory to minimize vibration. Compressors shall be capable of operating at partial-load conditions without increased vibration over the normal vibration at full load operation and shall be capable of continuous operation down to the lowest step of unloading as specified. Compressors of size 10 horsepower and above shall have an oil lubrication system of the reversible, forced-feed type with oil strainer. Shaft seal in open-type units shall be mechanical type. Piston speed for open-type compressors shall not exceed the manufacturer's recommendation or 1200 fpm, whichever is less. Compressors shall include: a. b. c. Vertical, V, W, or radial cylinder design Oil lubrication Integrally cast block of close-grained iron or cast aluminum block with hardened steel cylinder sleeves Oil-level bull's eye Cast cylinder heads Cast-aluminum or forged-steel connecting rods SECTION 23 64 10 Page 16
d. e. f.
123044
g. h. i. j.
Cast iron or forged-steel crankshaft Main bearings of the sleeve-insert type Crankcase oil heaters controlled as recommended by the manufacturer Suction and discharge refrigerant service valves that are flange connected, wrench operated, with cap A strainer on the suction side of the compressor [A hot-gas muffler to reduce vibration and noise from pulsations] Scroll Compressor(s)
k. l.
2.6.5.2
Compressors shall be of the hermetically sealed design. Compressors shall be mounted on vibration isolators to minimize vibration and noise. Rotating parts shall be statically and dynamically balanced at the factory to minimize vibration. Lubrication system shall be centrifugal pump type equipped with a means for determining oil level and an oil charging valve. Crankcase oil heater shall be provided if standard or if available as an option. If provided, the crankcase oil heater shall be controlled as recommended by the manufacturer. 2.5.5.1 Rotary Screw Compressor(s)
Compressors shall operate stably for indefinite time periods at any stage of capacity reduction without hot-gas bypass. Provision shall be made to insure proper lubrication of bearings and shaft seals on shutdown with or without electric power supply. Rotary screw compressors shall include: a. An open or hermetic, positive displacement, oil-injected design directly driven by the compressor driver. Compressor shall allow access to internal compressor components for repairs, inspection, and replacement of parts. Rotors shall be solid steel, possessing sufficient rigidity for proper operation. A maximum rotor operating speed no greater than 3600 RPM. iron rotor housing provide cast
b.
c.
d.
Casings of cast iron, precision machined for minimal clearance about periphery of rotors with minimal clearance at rotor tops and rotor ends. A lubrication system of the forced-feed type that provides oil at the proper pressure to all parts requiring lubrication. Bearing housing shall be conservatively loaded and rated for an L(10) life of not less than 200,000 hours. Shaft main bearings of the sleeve type with heavy duty bushings or rolling element type in accordance with ABMA 9 or ABMA 11. A differential oil pressure or flow cutout to allow the compressor to operate only when the required oil pressure or flow is provided to the bearings. A temperature- or pressure-initiated, hydraulically actuated, SECTION 23 64 10 Page 17
e.
f.
g.
h.
123044
single-slide-valve, capacity-control system to provide minimum automatic capacity modulation from 100 percent to 15 percent. i. An oil separator and oil return system to remove oil entrained in the refrigerant gas and automatically return the oil to the compressor. Crankcase oil heaters controlled as recommended by the manufacturer. Centrifugal Compressor(s)
j.
2.6.5.4
Centrifugal compressors shall be single or multistage, having dynamically balanced impellers, either direct or gear driven by the compressor driver. Impellers shall be over-speed tested at 1.2 times the impeller-shaft speed. Impeller shaft shall be heat-treated alloy steel with sufficient rigidity for proper operation at any required operating speed. Centrifugal compressors shall include: a. Shaft main bearings that are the rolling element type in accordance with ABMA 9 or ABMA 11, journal type with bronze or babbitt liners, or of the aluminum-alloy one-piece insert type. Bearings shall be rated for an L(10) life of not less than 200,000 hours. Casing of cast iron, aluminum, or steel plate with split sections gasketed and bolted or clamped together. Lubrication system of the forced-feed type that provides oil at the proper pressure to all parts requiring lubrication. Provisions to ensure proper lubrication of bearings and shaft seals prior to starting and upon stopping with or without electric power supply. On units providing forced-feed lubrication prior to starting, a differential oil pressure cutout interlocked with the compressor starting equipment shall allow the compressor to operate only when the required oil pressure is provided to the bearings. Oil sump heaters controlled as recommended by the manufacturer. Temperature-or pressure-actuated prerotation vane or suction damper to provide automatic capacity modulation from 100 percent capacity to 10 percent capacity. If operation to 10 percent capacity cannot be achieved without providing hot-gas bypass, then the Contractor shall indicate in the equipment submittal the load percent at which hot gas bypass is required. Compressor Driver, Electric Motor
b.
c.
d.
e. f.
2.5.6
Motors, starters, [variable speed drives], wiring, etc. shall be in accordance with paragraph ELECTRICAL WORK. Motor starter shall be [unit mounted] [remote mounted] as indicated with starter type, wiring, and accessories coordinated with the chiller manufacturer. 2.6.7 Compressor Driver, Gas-Engine
Gas-engine compressor driver shall operate on natural gas and be in accordance with NFPA 37 and NFPA 54. Engine shall be designed for stationary applications and include all ancillaries necessary for operation. Engine shall be a manufacturer's standard production model and be specifically designed for chiller operation. Engine shall include as a minimum a [heavy duty industrial] [standard automotive] grade block, SECTION 23 64 10 Page 18
123044
starting system, lubrication system, coolant system, engine heat exchanger, [engine cooling radiator,] fuel supply system, electronic ignition, and controls package. Engine shall be [naturally aspirated], [supercharged,] or [turbocharged] and include appropriate air filters. Engine shall be 2or 4-stroke-cycle and compression-ignition type. Engine shall be vertical in-line, V- or opposed-piston type, with a solid cast block or individually cast cylinders. Engine shall have a minimum of 2 cylinders. Opposed-piston type engines shall have not less than 4 cylinders. Engine block shall have a coolant drain port.
2.6.7.1
Starting System
Engine starting system shall be the [electric] [pneumatic] type and be of sufficient capacity, at the maximum temperature specified, to crank the engine without damage or overheating. [Electric starting system shall operate on a [24] [_____]-volt DC system utilizing a negative circuit ground. A starting battery system shall be provided and shall include the battery, corrosion resistant battery rack, intercell connectors, spacers, automatic battery charger with overcurrent protection, metering and relaying. Battery shall be in accordance with SAE J537. Battery charger shall conforming to UL 1236 and be the current-limiting type with overcurrent protection.] [Pneumatic starting system shall be as specified in Section 22 00 00 PLUMBING, GENERAL PURPOSE, for a working pressure of 150 psi.] 2.6.7.2 Lubrication System
Engine shall be provided with a pressurized oil lubrication system. System shall include a lubrication oil pump that is engine driven. One full-flow filter shall be provided for each pump. Filters shall be readily accessible and capable of being changed without disconnecting the piping or disturbing other components. System pressure shall be regulated as recommended by the engine manufacturer. A pressure relief valve shall be provided on the crankcase. Crankcase breathers shall be piped to the outside. System shall be readily accessible for servicing such as draining, refilling, and overhauling. 2.6.7.3 Coolant System
Engine shall include an automatic engine jacket water cooling system. Water shall be circulated through the system with an engine-driven circulating pump. [System coolant shall use a combination water and ethylene-glycol sufficient for freeze protection at the minimum temperature specified.] [2.6.7.4 Engine Heat Exchanger
Engine heat exchanger shall be of the shell-and-tube type construction and be in accordance with ASME BPVC SEC VIII D1. Shell material shall be carbon steel. Tubes shall be seamless copper or copper-nickel. Tubes shall be individually replaceable. Unit's waterside working pressure shall be rated for not less than 150 psig and factory tested at 150 percent of design working pressure. Water connections larger than 3 inches shall be ASME Class 1500 flanged. Unit shall be provided with gasketed removable covers, drains, and vents.
SECTION 23 64 10
Page 19
123044
][2.6.7.5
Engine Cooling Radiator
Heat exchanger may be factory coated with corrosive resistant film, provided that correction measures are taken to restore the heat rejection capability of the radiator to the initial design requirement via over sizing, or other compensating methods. Internal surfaces shall be compatible with liquid fluid coolant used. Materials and coolant are subject to approval by the Contracting Officer. Heat exchangers shall be the pressure type incorporating a pressure valve, vacuum valve and a cap. Caps shall be designed for pressure relief prior to removal. Each heat exchanger and the entire cooling system shall be capable of withstanding a minimum pressure of 7 psi and shall be protected with a strong grille or screen guard. Each heat exchanger shall have at least 2 tapped holes; one shall be equipped with a drain cock, the rest shall be plugged. ]2.6.7.6 Fuel Supply System
Engine fuel supply system shall be factory mounted. System shall include as a minimum a solenoid shut-off valve, a gas pressure regulator, and carburetors (including a throttle body assembly) or fuel injectors. 2.6.7.7 Controls Package
The controls for the gas-engine shall be incorporated into the overall controls package for the water chiller. The engine controls shall be capable of monitoring, displaying, and controlling, as applicable, the following conditions. a. b. c. d. e. f. g. Coolant-fluid inlet and outlet temperatures Lubricating-oil inlet and outlet temperatures and pressures Engine run-time hours Engine current status mode (on/off) Engine speed Percent engine load Engine jacket temperature Exhaust Piping
2.6.7.8
Exhaust piping shall be ASTM A53/A53M Schedule 40 seamless black iron, exhaust piping installation shall be per the engine manufacturer's recommendations, except as modified herein. Horizontal sections of exhaust piping shall be sloped downward away from the engine to a drip leg for collection of condensate with drain valve and cap. Changes in direction shall be long radius. Exhaust piping and mufflers shall be insulated in accordance with Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS. Vertical exhaust piping shall be provided with a hinged, gravity-operated, self-closing, rain cover. 2.6.7.9 Exhaust Muffler
Engine shall be provided with a chamber type exhaust muffler. The muffler shall be of welded steel and designed for [outside] [inside] [vertical] [horizontal] mounting. Eyebolts, lugs, flanges, or other items shall be SECTION 23 64 10 Page 20
123044
provided as necessary for support in the location and position indicated. Pressure drop through the muffler shall not exceed the recommendations of the engine manufacturer. Outside mufflers shall be zinc coated or painted with high temperature [_____] degrees resisting paint. The muffler and exhaust piping together shall reduce the noise level to less than [_____] dBa at a distance of 75 feet from the end of the exhaust piping with the chiller operating at 100 percent of rated output capacity. The muffler shall have a drain valve, nipple, and cap at the low-point of the muffler. 2.6.7.10 Exhaust System Connections
Flexible connectors shall be provided at the exhaust piping connection to the engine. An expansion joint shall be provided in the exhaust piping at the muffler connection. Flexible connectors and expansion joints shall have flanged connections. Flexible sections shall be made of convoluted seamless tube without joints or packing. Expansion joints shall be the bellows type. Expansion and flexible elements shall be stainless steel suitable for engine exhaust gas at 1200 degrees F. Flexible connectors and expansion joints shall be capable of absorbing vibration from the engine and compensation for thermal expansion and contraction. 2.6.8 Compressor Driver, Steam Turbine
Steam turbine shall conform to NEMA SM 23 and be suitable for direct connection to the compressor. Turbine shall have a capacity 10 percent greater than the compressor brake horsepower requirement at full-load condition. Steam strainer shall be either internally mounted or installed in connecting piping. Turbine shall include sentinel warning valve, forced-feed lubrication, oil cooler, oil reservoir, oil relief valve, oil piping, oil-pressure gauge, tachometer, and gland-seal piping if a condensing turbine is used. If a non-condensing turbine is used, provision shall be made for drain piping. The turbine shall be suitable for automatic control. An overspeed trip governor shall be provided to shut off the steam supply at 115 percent of design speed. Provision shall be made to stop the turbine upon operation of the compressor safety devices and upon power failure by the use of a solenoid trip on the emergency overspeed governor. Turbine shall be governed by a pneumatically controlled hydraulic governor during automatic operation and with a manual control effective during failure of the air supply. Pneumatic valve shall be actuated by a temperature controller with its sensing element in contact with the chilled water. Turbine shall be designed to operate at the steam pressure and exhaust conditions indicated. If the turbine is a condensing type, a surface-type steam condenser complete with single-stage air ejector, inter- and after-condenser, electric-driven dual condensate pumps, atmospheric relief valve, and expansion joint shall be furnished. 2.5.7 Compressor Driver Connections
[Each compressor shall be driven by a V-belt drive or direct connected through a flexible coupling, except that flexible coupling is not required on hermetic units. V-belt drives shall be designed for not less than 150 percent of the driving motor capacity. Flexible couplings shall be of the type that does not require lubrication.] [Each machine driven through speed-increasing gears shall be so designed as to assure self-alignment, interchangeable parts, proper lubrication system, and minimum unbalanced forces. Bearings shall be of the sleeve or roller type. Gear cases shall be oil tight. Shaft extensions shall be provided with seals to retain oil and exclude all dust.]
SECTION 23 64 10
Page 21
123044
2.5.8
Water Cooler (Evaporator)
Cooler shall be of the shell-and-coil or shell-and-tube type design. Condenser's refrigerant side shall be designed and factory pressure tested to comply with ANSI/ASHRAE 15 & 34. Condenser's water side shall be designed and factory pressure tested for not less than [150] [250] psi. Cooler shell shall be constructed of seamless or welded steel. Coil bundles shall be totally removable and arranged to drain completely. Tubes shall be seamless copper, plain, integrally finned with smooth bore or integrally finned with enhanced bore. Each tube shall be individually replaceable. Tubes shall be installed into carbon mild steel tube sheets by rolling. Tube baffles shall be properly spaced to provide adequate tube support and cross flow. Performance shall be based on a water velocity not less than 3 fps Performance shall be based on a water velocity not less than 3 fps nor more than 12 fps and a fouling factor of [0.0001 h(ft2)(degrees F)/Btu] [0.00025 h(ft2)(degrees F)/Btu] [0.0005 h(ft2)(degrees F)/Btu]. 2.5.9 Air-Cooled Condenser Coil
Condenser coil shall be of the extended-surface fin-and-tube type and shall be constructed of seamless [copper] [or] [aluminum] tubes with compatible [copper] [or] [aluminum] fins. Fins shall be soldered or mechanically bonded to the tubes and installed in a metal casing. Coils shall be circuited and sized for a minimum of 5 degrees F subcooling and full pumpdown capacity. Coil shall be factory leak and pressure tested after assembly in accordance with ANSI/ASHRAE 15 & 34. [Coil shall be entirely coated with the manufacturer's standard epoxy or vinyl coatingfor outdoor installation. Coil coating shall withstand 3000 hour exposure to salt spray test in accordance with ASTM B117, using a 5 percent sodium chloride solution.] 2.6.12 Water-Cooled Condenser Coil
Condenser shall be of the shell-and-coil or shell-and-tube type design. Condenser's refrigerant side shall be designed and factory pressure tested to comply with ANSI/ASHRAE 15 & 34. Condenser's water side shall be designed and factory pressure tested for not less than [150] [250] psi. Condensers shall be complete with refrigerant relief valve/rupture disc assembly, water drain connections, and refrigerant charging valve. Low pressure refrigerant condenser shall be provided with a purge valve located at the highest point in the condenser to purge non-condensibles trapped in the condenser. Condenser shell shall be constructed of seamless or welded steel. Coil bundles shall be totally removable and arranged to drain completely. Tubes shall be seamless copper, plain, integrally finned with smooth bore or integrally finned with enhanced bore. Each tube shall be individually replaceable, except for the coaxial tubes. Tube baffles shall be properly spaced to provide adequate tube support and cross flow. Performance shall be based on water velocities not less than 3 fps nor more than 12 fps and a fouling factor of [0.00025 h(ft2)(degrees F)/Btu)] [0.0005 h(ft2)(degrees F)/Btu]. Water-cooled condensers may be used for refrigerant storage in lieu of a separate liquid receiver, if the condenser storage capacity is 5 percent in excess of the fully charged system for single packaged systems. 2.6.13 Heat Recovery Condenser Coil
Condenser shall be of the shell-and-coil or shell-and-tube type design and shall not be a part of the standard condenser. Condenser shall be provided SECTION 23 64 10 Page 22
123044
and installed by the chiller manufacturer. Condenser's refrigerant side shall be designed and factory pressure tested to comply with ANSI/ASHRAE 15 & 34. Condenser's water side shall be designed and factory pressure tested for not less than [150] [250] psi. Condenser shall have performance characteristics as indicated on the drawings. Condenser shell shall be constructed of seamless or welded steel. Coil bundles shall be totally removable and arranged to drain completely. Tubes shall be seamless copper, plain, integrally finned with smooth bore or integrally finned with enhanced bore. Each tube shall be individually replaceable, except for the coaxial tubes. Tube baffles shall be properly spaced to provide adequate tube support and cross flow. Performance shall be based on water velocities not less than 3 fps nor more than 12 fps and a fouling factor of[0.00025] [0.0005]. 2.6.14 Receivers
Receiver shall bear a stamp certifying compliance with ASME BPVC SEC VIII D1 and shall meet the requirements of ANSI/ASHRAE 15 & 34. Inner surfaces shall be thoroughly cleaned by sandblasting or other approved means. Each receiver shall have a storage capacity not less than 20 percent in excess of that required for the fully-charged system. Each receiver shall be equipped with inlet, outlet drop pipe, drain plug, purging valve, relief valves of capacity and setting required by ANSI/ASHRAE 15 & 34, and two bull's eye liquid-level sight glasses. Sight glasses shall be in the same vertical plane, 90 degrees apart, perpendicular to the axis of the receiver, and not over 3 inches horizontally from the drop pipe measured along the axis of the receiver. In lieu of bull's eye sight glass, external gauge glass with metal glass guard and automatic closing stop valves may be provided. 2.6.15 Chiller Purge System
Chillers which operate at pressures below atmospheric pressure shall be provided with a purge system. Purge system shall automatically remove air, water vapor, and non-condensible gases from the chiller's refrigerant. Purge system shall condense, separate, and return all refrigerant back to the chiller. An oil separator shall be provided with the purge system if required by the manufacturer. Purge system shall not discharge to occupied areas, or create a potential hazard to personnel. Purge system shall include a purge pressure gauge, number of starts counter, and an elapsed time meter. Purge system shall include lights or an alarm which indicate excessive purge or an abnormal air leakage into chiller. [2.6.16 Tools
One complete set of special tools, as recommended by the manufacturer for field maintenance of the system, shall be provided. Tools shall be mounted on a tool board in the equipment room or contained in a toolbox as directed by the Contracting Officer.] 2.6 2.7.1 ACCESSORIES Refrigerant Leak Detector
Detector shall be the continuously-operating, halogen-specific type. Detector shall be appropriate for the refrigerant in use. Detector shall be specifically designed for area monitoring and shall include [a single sampling point] [[_____] sampling points] installed where indicated. Detector design and construction shall be compatible with the temperature, SECTION 23 64 10 Page 23
123044
humidity, barometric pressure and voltage fluctuations of the operating area. Detector shall have an adjustable sensitivity such that it can detect refrigerant at or above 3 parts per million (ppm). Detector shall be supplied factory-calibrated for the appropriate refrigerant(s). Detector shall be provided with an alarm relay output which energizes when the detector detects a refrigerant level at or above the TLV-TWA (or toxicity measurement consistent therewith) for the refrigerant(s) in use. The detector's relay shall be capable of initiating corresponding alarms and ventilation systems as indicated on the drawings. Detector shall be provided with a failure relay output that energizes when the monitor detects a fault in its operation. [Detector shall be capable with the facility's energy management and control system (EMSS). The EMCS shall be capable of generating an electronic log of the refrigerant level in the operating area, monitoring for detector malfunctions, and monitoring for any refrigerant alarm conditions.] 2.7.2 Refrigerant Relief Valve/Rupture Disc Assembly
The assembly shall be a combination pressure relief valve and rupture disc designed for refrigerant usage. The assembly shall be in accordance with ASME BPVC SEC VIII D1 and ANSI/ASHRAE 15 & 34. The assembly shall be provided with a pressure gauge assembly which will provide local indication if a rupture disc is broken. Rupture disc shall be the non-fragmenting type. 2.7.3 Refrigerant Signs
Refrigerant signs shall be a medium-weight aluminum type with a baked enamel finish. Signs shall be suitable for indoor or outdoor service. Signs shall have a white background with red letters not less than 0.5 inches in height. 2.7.3.1 Installation Identification
Each new refrigerating system shall be provided with a refrigerant sign which indicates the following as a minimum: a. b. c. d. Contractor's name. Refrigerant number and amount of refrigerant. The lubricant identity and amount. Field test pressure applied. Controls and Piping Identification
2.7.3.2
Refrigerant systems containing more than 110 lbof refrigerant shall be provided with refrigerant signs which designate the following as a minimum: a. Valves or switches for controlling the refrigerant flow [, the ventilation system,] and the refrigerant compressor(s). Pressure limiting device(s). Refrigerant Recovery/Recycle System
b. 2.7.4
A manually initiated refrigerant recovery/recycle system shall be provided, consisting of a motor-driven, air- or water-cooled, reciprocating SECTION 23 64 10 Page 24
123044
condensing unit and a receiver of sufficient capacity to store the entire refrigerant charge of the largest water-chilling system. For refrigerants with atmospheric pressure boiling temperature below 68 degrees F the receiver shall be sized so that it is no more than 80 percent full at 90 degrees F. For refrigerants with atmospheric pressure boiling temperature above 68 degrees F, the receiver shall be sized so that it is no more than 90 percent full at 90 degrees F. The recovery/recycle system condensing unit shall be assembled as a complete unit and meet the requirements of ANSI/ASHRAE 15 & 34. The system components shall be portable and shall include all valves, connections, and controls required for operation. Receiver and relief devices shall conform to the requirements of ASME BPVC SEC VIII D1. The recovery/recycle system shall be tested and listed to conform to AHRI 740 for refrigerant recovery/recycle systems by a recognized national testing laboratory. For refrigerants with atmospheric pressure boiling temperature below 68 degrees F, the recovery/recycle unit shall have an AHRI 740 vapor refrigerant recovery rate of no less than 17.0 lb/minute. For refrigerants with atmospheric pressure boiling temperature above 68 degrees F, the recovery/recycle unit shall have an AHRI 740 vapor refrigerant recovery rate of no less than 2.2 lb/minute. 2.7.5 2.7.5.1 Automatic Tube Brush Cleaning System Brush and Basket Sets
One brush and basket set (one brush and two baskets) shall be furnished for each condenser tube. Brushes shall be made of nylon bristles, with titanium wire. Baskets shall be polypropylene. 2.7.5.2 Flow-Diverter Valve
Each system shall be equipped with one flow-diverter valve specifically designed for the automatic tube brush cleaning system and have parallel flow connections. The flow-diverter valve shall be designed for a working pressure of [150] [250] psig. End connections shall be flanged. Each valve shall be provided with an electrically operated air solenoid valve and position indicator. 2.7.5.3 Control Panel
The control panel shall provide signals to the diverter valve at a preset time interval to reverse water flow to drive the tube brushes down the tubes and then signal the valve to reverse the water flow to drive the brushes back down the tubes to their original position. The controller shall have the following features as a minimum: a. b. c. d. e. f. Timer to initiate the on-load cleaning cycle. Manual override of preset cleaning cycle. Power-on indicator. Diverter-position indicator. Cleaning-cycle-time adjustment Flow-switch bypass.
SECTION 23 64 10
Page 25
123044
2.6.1
Gaskets
Gaskets shall conform to ASTM F 104 - classification for compressed sheet with nitrile binder and acrylic fibers for maximum 700 degrees F service. 2.6.2 Bolts and Nuts
Bolts and nuts, except as required for piping applications, shall be in accordance with ASTM A307. The bolt head shall be marked to identify the manufacturer and the standard with which the bolt complies in accordance with ASTM A307. 2.7 2.7.1 FABRICATION Factory Coating
Unless otherwise specified, equipment and component items, when fabricated from ferrous metal, shall be factory finished with the manufacturer's standard finish, except that items located outside of buildings shall have weather resistant finishes that will withstand [125] [5003000] hours exposure to the salt spray test specified in ASTM B117 using a 5 percent sodium chloride solution. Immediately after completion of the test, the specimen shall show no signs of blistering, wrinkling, cracking, or loss of adhesion and no sign of rust creepage beyond 1/8 inch on either side of the scratch mark. Cut edges of galvanized surfaces where hot-dip galvanized sheet steel is used shall be coated with a zinc-rich coating conforming to ASTM D 520, Type I. 2.7.2 Factory Applied Insulation
Chiller shall be provided with factory installed insulation on surfaces subject to sweating including the water cooler, suction line piping, economizer, and cooling lines. Insulation on heads of coolers may be field applied, however it shall be installed to provide easy removal and replacement of heads without damage to the insulation. Where motors are the gas-cooled type, factory installed insulation shall be provided on the cold-gas inlet connection to the motor per manufacturer's standard practice. Factory insulated items installed outdoors are not required to be fire-rated. As a minimum, factory insulated items installed indoors shall have a flame spread index no higher than 75 and a smoke developed index no higher than 150. Factory insulated items (no jacket) installed indoors and which are located in air plenums, in ceiling spaces, and in attic spaces shall have a flame spread index no higher than 25 and a smoke developed index no higher than 50. Flame spread and smoke developed indexes shall be determined by ASTM E 84. Insulation shall be tested in the same density and installed thickness as the material to be used in the actual construction. Material supplied by a manufacturer with a jacket shall be tested as a composite material. Jackets, facings, and adhesives shall have a flame spread index no higher than 25 and a smoke developed index no higher than 50 when tested in accordance with ASTM E 84. 2.8 2.8.1 FACTORY TESTS Chiller Performance Test
The Contractor and proposed chiller manufacturer shall be responsible for performing the chiller factory test to validate the specified full load capacity, full load EER, and [IPLV] [NPLV] in accordance with AHRI 550/590 except as indicated. [The chiller factory test shall be performed in the SECTION 23 64 10 Page 26
123044
presence of a Government representative.] The Contractor and chiller manufacturer shall provide to the Government a certified chiller factory test report in accordance with AHRI 550/590 to confirm that the chiller performs as specified. Tests shall be conducted in an ARI certified test facility in conformance with AHRI 550/590 procedures and tolerances, except as indicated. At a minimum, chiller capacity shall be validated to meet the scheduled requirements indicated on the drawings. Tolerance or deviation shall be in strict accordance with AHRI 550/590. Stable operation at minimum load of 10 percent of total capacity shall be demonstrated during the factory test. 2.8.1.1 Temperature Adjustments
Temperature adjustments shall adhere to AHRI 550/590 to adjust from the design fouling factor to the clean tube condition. Test temperature adjustments shall be verified prior to testing by the manufacturer. There shall be no exceptions to conducting the test with clean tubes with the temperature adjustments per AHRI 550/590. The manufacturer shall clean the tubes, if necessary, prior to testing to obtain a test fouling factor of 0.0000. 2.8.1.2 Test Instrumentation
The factory test instrumentation shall be per AHRI 550/590 and the calibration shall be traceable to the National Institute of Standards and Technology. 2.8.1.3 Test Report
A certified test report of all data shall be forwarded to the Government for approval prior to project acceptance. Calibration curves and information sheets for all instrumentation shall be provided. 2.8.1.4 Equipment Adjustments
If the equipment fails to perform within allowable tolerances, the manufacturer shall be allowed to make necessary revisions to his equipment and retest as required. [The manufacturer shall assume all expenses incurred by the Government to witness the retest.] 2.8.2 Chiller Sound Test
Chillers shall be sound tested at the factory prior to shipment to confirm the sound pressure level specified herein. Tests and data shall be conducted and measured in strict accordance with AHRI 575 at the full load system operating conditions. The chiller sound pressure level, in decibels (dB), with a reference pressure of 20 micropascals, shall not exceed [85] [90] [_____] dB, A weighted. Ratings shall be in accordance with AHRI 575. No reduction of entering condenser water temperature or raising of leaving chilled water temperature shall be allowed. A minimum of 75 percent of the sound data points shall be taken along the length of the machine, and established as the minimum percentage of total possible points used to determine sound levels. In the event that the chiller does not meet the dBA sound pressure level, the manufacturer shall, at his expense, provide sufficient attenuation to the machine to meet the specified value. This attenuation shall be applied in such a manner that it does not hinder the operation or routine maintenance procedures of the chiller. The attenuation material, adhesives, coatings, and other accessories shall have surface burning characteristics as determined by ASTM E 84. SECTION 23 64 10 Page 27
123044
2.9
SUPPLEMENTAL COMPONENTS/SERVICES
2.10.1
Chilled and Condenser Water Piping and Accessories
Chilled and condenser water piping and accessories shall be provided and installed in accordance with Section 23 64 26 CHILLED, CHILLED-HOT, AND CONDENSER WATER PIPING SYSTEMS. 2.10.2 Refrigerant Piping
Refrigerant piping for split-system water chillers shall be provided and installed in accordance with Section 23 23 00 REFRIGERANT PIPING. 2.10.3 Cooling Tower
Cooling towers shall be provided and installed in accordance with Section 23 65 00 COOLING TOWERS.
2.9.1
Temperature Controls
Chiller control packages shall be fully coordinated with and integrated [ into the temperature control system specified in Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEM and 23 09 23 LONWORKS DIRECT DIGITAL CONTROL FOR HVAC AND OTHER BUILDING CONTROL SYSTEMS 23 09 23.13 202 BACnet DIRECT DIGITAL CONTROL SYSTEMS FOR HVAC] [into the existing air-conditioning system]. PART 3 3.1 EXECUTION INSTALLATION
Installation of water chiller systems including materials, installation, workmanship, fabrication, assembly, erection, examination, inspection, and testing shall be in accordance with the manufacturer's written installation instructions, including the following:. Provide chiller with single point power connection equipped with disconnecting means. [1. 3.1.1 Water chiller - installation instructions]
Connections to Existing Systems
Notify the Contracting Officer in writing at least 15 calendar days prior to the date the connections are required. Obtain approval before interrupting service. Furnish materials required to make connections into existing systems and perform excavating, backfilling, compacting, and other incidental labor as required. Furnish labor and tools for making actual connections to existing systems. 3.1.1 3.1.1.1 Refrigeration System Equipment
Refrigeration equipment and the installation thereof shall conform to ANSI/ASHRAE 15 & 34. Necessary supports shall be provided for all equipment, appurtenances, and pipe as required, including frames or supports for compressors, pumps, cooling towers, condensers, water coolers, SECTION 23 64 10 Page 28
123044
and similar items. Compressors shall be isolated from the building structure. If mechanical vibration isolators are not provided, vibration absorbing foundations shall be provided. Each foundation shall include isolation units consisting of machine and floor or foundation fastenings, together with intermediate isolation material. Other floor-mounted equipment shall be set on not less than a 6 inch concrete pad doweled in place. Concrete foundations for floor mounted pumps shall have a mass equivalent to three times the weight of the components, pump, base plate, and motor to be supported. In lieu of concrete pad foundation, concrete pedestal block with isolators placed between the pedestal block and the floor may be provided. Concrete pedestal block shall be of mass not less than three times the combined pump, motor, and base weights. Isolators shall be selected and sized based on load-bearing requirements and the lowest frequency of vibration to be isolated. Isolators shall limit vibration to [_____] percent at lowest equipment rpm. Lines connected to pumps mounted on pedestal blocks shall be provided with flexible connectors. Foundation drawings, bolt-setting information, and foundation bolts shall be furnished prior to concrete foundation construction for all equipment indicated or required to have concrete foundations. Concrete for foundations shall be as specified in Section 03 30 00 CAST-IN-PLACE CONCRETE. Equipment shall be properly leveled, aligned, and secured in place in accordance with manufacturer's instructions. 3.1.1.2 a. Field Refrigerant Charging
Initial Charge: Upon completion of all the refrigerant pipe tests, the vacuum on the system shall be broken by adding the required charge of dry refrigerant for which the system is designed, in accordance with the manufacturer's recommendations. Contractor shall provide the complete charge of refrigerant in accordance with manufacturer's recommendations. Upon satisfactory completion of the system performance tests, any refrigerant that has been lost from the system shall be replaced. After the system is fully operational, service valve seal caps and blanks over gauge points shall be installed and tightened. Refrigerant Leakage: If a refrigerant leak is discovered after the system has been charged, the leaking portion of the system shall immediately be isolated from the remainder of the system and the refrigerant shall be pumped into the system receiver or other suitable container. The refrigerant shall not be discharged into the atmosphere. Contractor's Responsibility: The Contractor shall, at all times during the installation and testing of the refrigeration system, take steps to prevent the release of refrigerants into the atmosphere. The steps shall include, but not be limited to, procedures which will minimize the release of refrigerants to the atmosphere and the use of refrigerant recovery devices to remove refrigerant from the system and store the refrigerant for reuse or reclaim. At no time shall more than 3 ounces of refrigerant be released to the atmosphere in any one occurrence. Any system leaks within the first year shall be repaired in accordance with the specified requirements including material, labor, and refrigerant if the leak is the result of defective equipment, material, or installation. Oil Charging
b.
c.
3.1.1.3
Except for factory sealed units, two complete charges of lubricating oil for each compressor crankcase shall be furnished. One charge shall be used SECTION 23 64 10 Page 29
123044
during the performance testing period, and upon the satisfactory completion of the tests, the oil shall be drained and replaced with the second charge. 3.1.3 Mechanical Room Ventilation
Mechanical ventilation systems shall be in accordance with Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEM. 3.1.2 Field Applied Insulation
Field installed insulation shall be as specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS, except as defined differently herein. 3.1.3 Field Painting
Painting required for surfaces not otherwise specified, and finish painting of items only primed at the factory are specified in Section 09 90 00 PAINTS AND COATINGS. 3.2 MANUFACTURER'S FIELD SERVICE
The services of a factory-trained representative shall be provided for [_____]2 days. The representative shall advise on the following: a. Hermetic machines: (1) Testing hermetic water-chilling unit under pressure for refrigerant leaks; evacuation and dehydration of machine to an absolute pressure of not over 300 microns. Charging the machine with refrigerant. Starting the machine.
(2) (3) b.
Open Machines: (1) (2) (3) Erection, alignment, testing, and dehydrating. Charging the machine with refrigerant. Starting the machine.
3.3
CLEANING AND ADJUSTING
Equipment shall be wiped clean, with all traces of oil, dust, dirt, or paint spots removed. Temporary filters shall be provided for all fans that are operated during construction, and new filters shall be installed after all construction dirt has been removed from the building. System shall be maintained in this clean condition until final acceptance. Bearings shall be properly lubricated with oil or grease as recommended by the manufacturer. Belts shall be tightened to proper tension. Control valves and other miscellaneous equipment requiring adjustment shall be adjusted to setting indicated or directed. Fans shall be adjusted to the speed indicated by the manufacturer to meet specified conditions. At least one week before the official equipment warranty start date, all condenser coils on air-cooled water chillers and split-system water chillers shall be cleaned in accordance with the chiller manufacturer's instructions. This work covers two coil cleanings. The condenser coils shall be cleaned with SECTION 23 64 10 Page 30
123044
an approved coil cleaner by a service technician, factory trained by the chiller manufacturer. The condenser coil cleaner shall not have any detrimental affect on the materials or protective coatings on the condenser coils. Testing, adjusting, and balancing shall be as specified in Section 23 05 93 TESTING, ADJUSTING, AND BALANCING FOR HVAC. 3.4 3.4.1 a. FIELD ACCEPTANCE TESTING Test Plans Manufacturer's Test Plans: Within [120][_____] calendar days after contract award, submit the following plans: [(1) Water chiller - field acceptance test plan] Field acceptance test plans shall be developed by the absorption chiller manufacturer detailing recommended field test procedures for that particular type and size of equipment. Field acceptance test plans developed by the installing Contractor, or the equipment sales agency furnishing the equipment, will not be acceptable. The Contracting Officer will review and approve the field acceptance test plan for each of the listed equipment prior to commencement of field testing of the equipment. The approved field acceptance tests of the absorption chiller and subsequent test reporting. b. Coordinated testing: Indicate in each field acceptance test plan when work required by this section requires coordination with test work required by other specification sections. Furnish test procedures for the simultaneous or integrated testing of tower system controls which interlock and interface with controls factory prewired or external controls for the equipment provided under [Section 23 09 23 LONWORKS DIRECT DIGITAL CONTROL FOR HVAC AND OTHER BUILDING CONTROL SYSTEMS][Section 23 09 53.00 20, SPACE TEMPERATURE CONTROL SYSTEMS] [Section 23 09 23.13 20, BACNET DIRECT DIGITAL CONTROL SYSTEMS FOR HVAC]. Prerequisite testing: Absorption chillers for which performance testing is dependent upon the completion of the work covered by Section 23 05 93 TESTING, ADJUSTING, AND BALANCING FOR HVAC must have that work completed as a prerequisite to testing work under this section. Indicate in each field acceptance test plan when such prerequisite work is required. Test procedure: Indicate in each field acceptance test plan each equipment manufacturers published installation, start-up, and field acceptance test procedures. Include in each test plan a detailed step-by-step procedure for testing automatic controls provided by the manufacturer. Each test plan shall include the required test reporting forms to be completed by the Contractor's testing representatives. Procedures shall be structured to test the controls through all modes of control to confirm that the controls are performing with the intended sequence of control. Controller shall be verified to be properly calibrated and have the SECTION 23 64 10 Page 31
c.
d.
123044
proper set point to provide stable control of their respective equipment. eb. Performance variables: Each test plan shall list performance variables that are required to be measured or tested as part of the field test. Include in the listed variables performance requirements indicated on the equipment schedules on the design drawings. Chiller manufacturer shall furnish with each test procedure a description of acceptable results that have been verified. Chiller manufacturer shall identify the acceptable limits or tolerance within which each tested performance variable shall acceptably operate. f. Job specific: Each test plan shall be job specific and shall address the particular cooling towers and particular conditions which exist in this contract. Generic or general preprinted test procedures are not acceptable. Specialized components: Each test plan shall include procedures for field testing and field adjusting specialized components, such as hot gas bypass control valves, or pressure valves. Testing Each water chiller system shall be field acceptance tested in compliance with its approved field acceptance test plan and the resulting following field acceptance test report submitted for approval:. [1. b. Water chiller - field acceptance test report]
gc.
3.4.2 a.
Manufacturer's recommended testing: Conduct the manufacturer's recommended field testing in compliance with the approved test plan. Furnish a factory trained field representative authorized by and to represent the equipment manufacturer at the complete execution of the field acceptance testing. Operational test: Conduct a continuous 24 hour operational test for each item of equipment. Equipment shutdown before the test period is completed shall result in the test period being started again and run for the required duration. For the duration of the test period, compile an operational log of each item of equipment. Log required entries every two hours. Use the test report forms for logging the operational variables. Notice of tests: Conduct the manufacturer's recommended tests and the operational tests; record the required data using the approved reporting forms. Notify the Contracting Officer in writing at least 15 calendar days prior to the testing. Within 30 calendar days after acceptable completion of testing, submit each test report for review and approval. Report forms: Type data entries and writing on the test report forms. Completed test report forms for each item of equipment shall be reviewed, approved, and signed by the Contractor's test director. The manufacturer's field test representative shall review, approve, and sign the report of the manufacturer's recommended test. Signatures SECTION 23 64 10 Page 32
c.
d.
e.
123044
shall be accompanied by the person's name typed. f. Deficiency resolution: The test requirements acceptably met; deficiencies identified during the tests shall be corrected in compliance with the manufacturer's recommendations and corrections retested in order to verify compliance. SYSTEM PERFORMANCE TESTS General Requirements
3.5 3.5.1
Before each refrigeration system is accepted, tests to demonstrate the general operating characteristics of all equipment shall be conducted by a registered professional engineer or an approved manufacturer's start-up representative experienced in system start-up and testing, at such times as directed. Tests shall cover a period of not less than [48] [_____] hours for each system and shall demonstrate that the entire system is functioning in accordance with the drawings and specifications. Corrections and adjustments shall be made as necessary and tests shall be re-conducted to demonstrate that the entire system is functioning as specified. Prior to acceptance, service valve seal caps and blanks over gauge points shall be installed and tightened. Any refrigerant lost during the system startup shall be replaced. If tests do not demonstrate satisfactory system performance, deficiencies shall be corrected and the system shall be retested. Tests shall be conducted in the presence of the Contracting Officer. Water and electricity required for the tests will be furnished by the Government. Any material, equipment, instruments, and personnel required for the test shall be provided by the Contractor. Field tests shall be coordinated with Section 23 05 93 TESTING, ADJUSTING, AND BALANCING FOR HVAC. 3.5.2 Test Report
The report shall document compliance with the specified performance criteria upon completion and testing of the system. The report shall indicate the number of days covered by the tests and any conclusions as to the adequacy of the system. The report shall also include the following information and shall be taken at least three different times at outside dry-bulb temperatures that are at least 5 degrees F apart: a. b. Date and outside weather conditions. The load on the system based on the following: (1) (2) (3) (4) The refrigerant used in the system. Condensing temperature and pressure. Suction temperature and pressure. Running current, voltage and proper phase sequence for each phase of all motors. (5) The actual on-site setting of all operating and safety controls. (6) Chilled water pressure, flow and temperature in and out of the chiller. (7) The position of the [capacity-reduction gear] [gas supply control valve] [fuel oil supply valve] at machine off, one-third loaded, one-half loaded, two-thirds loaded, and fully loaded. 3.6 DEMONSTRATIONS
Contractor shall conduct a training course for the operating staff as SECTION 23 64 10 Page 33
123044
designated by the Contracting Officer. The training period shall consist of a total 8[_____] hours of normal working time and start after the system is functionally completed but prior to final acceptance tests. The field posted instructions shall cover all of the items contained in the approved operation and maintenance manuals as well as demonstrations of routine maintenance operations. -- End of Section --
SECTION 23 64 10
Page 34
123044
SECTION 23 64 26 CHILLED, CHILLED-HOT, AND CONDENSER WATER PIPING SYSTEMS 08/09 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) ANSI Z21.22/CSA 4.4 (1999; Addenda A 2000, Addenda B 2001; R 2004) Relief Valves for Hot Water Supply Systems
AMERICAN WELDING SOCIETY (AWS) AWS A5.8/A5.8M (2004) Specification for Filler Metals for Brazing and Braze Welding (2007; 5th Ed) Brazing Handbook (2010) Structural Welding Code - Steel (2005) Safety in Welding and Cutting and Allied Processes
AWS BRH AWS D1.1/D1.1M AWS Z49.1
ASME INTERNATIONAL (ASME) ASME B1.20.1 (1983; R 2006) Pipe Threads, General Purpose (Inch) (2010) Gray Iron Threaded Fittings; Classes 25, 125 and 250 (2009) Forged Fittings, Socket-Welding and Threaded (2001; R 2005) Cast Copper Alloy Solder Joint Pressure Fittings (2011) Nonmetallic Flat Gaskets for Pipe Flanges (2001; R 2010) Standard for Wrought Copper and Copper Alloy Solder Joint Pressure Fittings (2006) Standard for Cast Copper Alloy Fittings for Flared Copper Tubes (20062010) Malleable Iron Threaded Fittings, Classes 150 and 300 SECTION 23 64 26 Page 1
ASME B16.1
ASME B16.11
ASME B16.18
ASME B16.21
ASME B16.22
ASME B16.26
ASME B16.3
123044
ASME B16.39
(2009) Standard for Malleable Iron Threaded Pipe Unions; Classes 150, 250, and 300 (2007) Standard for Factory-Made Wrought Steel Buttwelding Fittings (2011) Building Services Piping (2005) Pressure Gauges and Gauge Attachments (2007; Addenda 2008; Addenda 2009) Boiler and Pressure Vessel Codes: Section VIII Rules for Construction of Pressure Vessel
ASME B16.9
ASME BPVC SEC VIII
ASTM INTERNATIONAL (ASTM) ASTM A53/A53M (2010) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless (2010) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process (2003; R 2009e1) Standard Specification for Welded and Seamless Carbon Steel and Austenitic Stainless Steel Pipe Nipples (2009) Standing Practice for Operating Salt Spray (Fog) Apparatus (2008) Standard Specification for Solder Metal (2010) Standard Specification for Seamless Copper Pipe, Standard Sizes (2009) Standard Specification for Composition Bronze or Ounce Metal Castings (2002; R 2010) Standard Specification for Seamless Copper Tube (2010) Standard Specification for Liquid and Paste Fluxes for Soldering of Copper and Copper Alloy Tube (2009) Standard Specification for Seamless Copper Water Tube (2007) Standard Specification for Thermoplastic Polyethylene Jacket for Electrical Wire and Cable (2006) PTFE Resin Skived Tape SECTION 23 64 26 Page 2
ASTM A653/A653M
ASTM A733
ASTM B117
ASTM B32
ASTM B42
ASTM B62
ASTM B75
ASTM B813
ASTM B88
ASTM D 2308
ASTM D 3308
123044
ASTM D 520 ASTM E 84
(2000; R 200511) Zinc Dust Pigment (2010b1a) Standard Test Method for Surface Burning Characteristics of Building Materials (1988; R 2010) Cast (All Temperatures and Pressures) and Welded Pipe Line Strainers (150 psig and 150 degrees F Maximum)
ASTM F 1199
HYDRAULIC INSTITUTE (HI) HI 1.1-1.2 (2008) Rotodynamic (Centrifugal) Pump for Nomenclature and Definitions
INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE) IEEE 515 (2004) Standard for the Testing, Design, Installation, and Maintenance of Electrical Resistance Heat Tracing for Industrial Applications MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS) MSS SP-110 (2010) Ball Valves Threaded, Socket-Welding, Solder Joint, Grooved and Flared Ends (2008) Standard Marking System for Valves, Fittings, Flanges and Unions (2009) Pipe Hangers and Supports Materials, Design and Manufacture, Selection, Application, and Installation (2002a) Butterfly Valves (2003) Pipe Hangers and Supports Selection and Application (ANSI Approved American National Standard) (2006) Gray Iron Gate Valves, Flanged and Threaded Ends (2005) Gray Iron Swing Check Valves, Flanged and Threaded Ends (2010) Ball Valves with Flanged or Butt-Welding Ends for General Service (2005a) Cast Iron Plug Valves, Flanged and Threaded Ends (2008) Bronze Gate, Globe, Angle and Check Valves (2002) Gray Iron Globe & Angle Valves SECTION 23 64 26 Page 3
MSS SP-25
MSS SP-58
MSS SP-67 MSS SP-69
MSS SP-70
MSS SP-71
MSS SP-72
MSS SP-78
MSS SP-80
MSS SP-85
123044
Flanged and Threaded Ends NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA 250 (2008) Enclosures for Electrical Equipment (1000 Volts Maximum) (2009) Motors and Generators (1977; R 2007) Energy Management Guide for Selection and Use of Single Phase Motors
NEMA MG 1 NEMA MG 11
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA 90A (2009; Errata 09-1) Standard for the Installation of Air Conditioning and Ventilating Systems
1.2
SYSTEM DESCRIPTION
Provide the water systems having the minimum service (design) temperature-pressure rating indicated. Provision of the piping systems, including materials, installation, workmanship, fabrication, assembly, erection, examination, inspection, and testing shall be in accordance with the required and advisory provisions of ASME B31.9 except as modified or supplemented by this specification section or design drawings. This specification section covers the water systems piping which is located within, on, and adjacent to building(s) within the building(s) 5 foot line. 1.3 SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are [for Contractor Quality Control approval.][for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] Submit the following submitted in accordance with Section 01 33 00.05 20 CONSTRUCTION SUBMITTAL PROCEDURES: SD-03 Product Data Grooved Mechanical Connections For Steel[; G][; G, [_____]] Grooved Mechanical Connections For Copper[; G][; G, [_____]] Calibrated Balancing Valves[; G][; G, [_____]] Automatic Flow Control Valves[; G][; G, [_____]] Pump Discharge Valve Water Temperature Mixing Valve[; G][; G, [_____]] Water Temperature Regulating Valves[; G][; G, [_____]] Water Pressure Reducing Valve Pressure Relief Valve Combination Pressure and Temperature Relief Valves SECTION 23 64 26 Page 4
123044
Expansion Joints[; G][; G, [_____]] Pumps[; G][; G, [_____]] Combination Strainer and Pump Suction Diffuser Expansion Tanks Air Separator Tanks Electrical Heat Tracing Water Treatment SystemsChilled Water Buffer Tanks[; G][; G, [_____] ] Proposed water treatment plan including a layout, control scheme, a list of existing make-up water conditions including the items listed in paragraph "Water Analysis", a list of chemicals, the proportion of chemicals to be added, the final treated water conditions, and a description of environmental concerns for handling the chemicals. SD-06 Test Reports Piping welds NDE report Pressure tests reports[; G][; G, [_____]] Report shall be provided in bound 8-1/2 by 11 inch booklets. In the reports, document all phases of the tests performed. Include initial test summaries, all repairs/adjustments made, and the final test results. Condenser Water Quality Test Reports[; G][; G, [_____]] Test reports, each month for a period of one year after project completion, in bound 8-1/2 by 11 inch booklets. In the reports, identify the chemical composition of the condenser water. Also include the comparison of the manufacturer's recommended operating conditions for the cooling tower and condenser in relation to the condition of the condenser water. Document in the report any required corrective action taken. One-Year Inspection Report For Cooling Water[; G][; G, [_____]] At the completion of one year of service, in bound 8-1/2 by 11 inch booklets. In the report, identify the condition of each cooling tower and condenser. Include a comparison of the condition of the cooling tower and condenser with the manufacturer's recommended operating conditions. Identify all actions taken by the Contractor and manufacturer to correct deficiencies during the first year of service. SD-07 Certificates Employer's Record Documents (For Welding) Welding Procedures and Qualifications SECTION 23 64 26 Page 5
123044
Certificates shall be submitted for the following items showing conformance with the referenced standards contained in this section.
SD-08 Manufacturer's Instructions Lesson plan for the Instruction Course[; G][; G, [_____]] SD-10 Operation and Maintenance Data Requirements for data packages are specified Section 01 78 23 24.05 20FACILITY OPERATION AND MAINTENANCE DATASUPPORT INFORMATION, except as supplemented and modified by this specification section. Submit spare parts data for each different item of equipment specified, with operation and maintenance data packages. Include a complete list of parts and supplies, with current unit prices and source of supply, a recommended spare parts list for 1 year of operation, and a list of the parts recommended by the manufacturer to be replaced on a routine basis. Submit a list of qualified permanent service organizations with operation and maintenance data packages. Include service organization addresses and service area or expertise. The service organizations shall be reasonably convenient to the equipment installation and be able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract. Water Treatment Systems[; G][; G, [_____]] An operation manual in bound 8-1/2 by 11 inch booklets listing step-by-step procedures required for system startup, operation, abnormal shutdown, emergency shutdown, and normal shutdown. Include testing procedures used in determining water quality. A maintenance manual in bound 8-1/2 by 11 inch booklets listing routine maintenance procedures, possible breakdowns and repairs, and a trouble shooting guide. Calibrated Balancing Valves, Data Package 3[; G][; G, [_____]] Automatic Flow Control Valves, Data Package 3[; G][; G, [_____]] Pump Discharge Valve, Data Package 2[; G][; G, [_____]] Water Temperature Mixing Valve, Data Package 3[; G][; G, [_____]] Water Temperature Regulating Valves, Data Package 3[; G][; G, [_____]] Water Pressure Reducing Valve, Data Package 3[; G][; G, [_____]] Pressure Relief Valve, Data Package 2[; G][; G, [_____]] Combination Pressure and Temperature Relief ValvesChilled Water SECTION 23 64 26 Page 6
123044
Buffer Tanks, Data Package 2[; G][; G, [_____]] Expansion Joints, Data Package 2[; G][; G, [_____]] Pumps, Data Package 3[; G][; G, [_____]] Combination Strainer and Pump Suction Diffuser, Data Package 2[; G ][; G, [_____]] Expansion Tanks, Data Package 2[; G][; G, [_____]] Air Separator Tanks, Data Package 2[; G][; G, [_____]] 1.4 MODIFICATIONS TO REFERENCES
In each of the publications referred to herein, consider the advisory provisions to be mandatory, as though the word, "shall" had been substituted for "should" wherever it appears. Interpret references in these publications to the "authority having jurisdiction", or words of similar meaning, to mean the Contracting Officer. 1.4.1 Definitions
For the International Code Council (ICC) Codes referenced in the contract documents, advisory provisions shall be considered mandatory, the word "should" shall be interpreted as "shall." Reference to the "code official" shall be interpreted to mean the "Contracting Officer." For Navy owned property, references to the "owner" shall be interpreted to mean the "Contracting Officer." For leased facilities, references to the "owner" shall be interpreted to mean the "lessor." References to the "permit holder" shall be interpreted to mean the "Contractor." 1.4.2 Administrative Interpretations
For ICC Codes referenced in the contract documents, the provisions of Chapter 1, "Administrator," do not apply. These administrative requirements are covered by the applicable Federal Acquisition Regulations (FAR) included in this contract and by the authority granted to the Officer in Charge of Construction to administer the construction of this project. References in the ICC Codes to sections of Chapter 1, shall be applied appropriately by the Contracting Officer as authorized by his administrative cognizance and the FAR. 1.5 SAFETY REQUIREMENTS
Exposed moving parts, parts that produce high operating temperature, parts which may be electrically energized, and parts that may be a hazard to operating personnel shall be insulated, fully enclosed, guarded, or fitted with other types of safety devices. Safety devices shall be installed so that proper operation of equipment is not impaired. 1.6 DELIVERY, STORAGE, AND HANDLING
Protect stored items from the weather, humidity and temperature variations, dirt and dust, or other contaminants. Proper protection and care of all material both before and during installation shall be the Contractor's responsibility. Any materials found to be damaged shall be replaced at the Contractor's expense. During installation, cap piping and similar openings to keep out dirt and other foreign matter. Any porous materials found to SECTION 23 64 26 Page 7
123044
be contaminated with mold or mildew will be replaced at the Contractor's expense. Non-porous materials found to be contaminated with mold or mildew will be disinfected and cleaned prior to installation. 1.7 1.7.1 PROJECT/SITE CONDITIONS Verification of Dimensions
The Contractor shall become familiar with all details of the work, verify all dimensions in the field, and advise the Contracting Officer of any discrepancy before performing any work. 1.7.2 Drawings
Because of the small scale of the drawings, it is not possible to indicate all offsets, fittings, and accessories that may be required. The Contractor shall carefully investigate the plumbing, fire protection, electrical, structural and finish conditions that would affect the work to be performed and shall arrange such work accordingly, furnishing required offsets, fittings, and accessories to meet such conditions. 1.7.3 Accessibility
Install all work so that parts requiring periodic inspection, operation, maintenance, and repair are readily accessible. Install concealed valves, expansion joints, controls, dampers, and equipment requiring access, in locations freely accessible through access doors. PART 2 2.1 PRODUCTS STANDARD COMMERCIAL PRODUCTS
Materials and equipment shall be standard products of a manufacturer regularly engaged in the manufacturing of such products, which are of a similar material, design and workmanship. The standard products shall have been in satisfactory commercial or industrial use for 2 years prior to bid opening. The two year use shall include applications of equipment and materials under similar circumstances and of similar size. The 2 years experience shall be satisfactorily completed by a product which has been sold or is offered for sale on the commercial market through advertisements, manufacturer's catalogs, or brochures. Products having less than a 2 year field service record shall be acceptable if a certified record of satisfactory field operation, for not less than 6000 hours exclusive of the manufacturer's factory tests, can be shown. System components shall be environmentally suitable for the indicated locations. The equipment items shall be supported by service organizations. These service organizations shall be reasonably convenient to the equipment installation and able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract. 2.2 STEEL PIPING
Water piping shall be steel pipe or copper tubing. Provide steel piping with a ANSI/ASME Class 125 service rating, which for 150 degrees F, the SECTION 23 64 26 Page 8
123044
pressure rating is 175 psig. 2.2.1 Pipe
Steel pipe, conform to ASTM A53/A53M, Schedule 40, Type E or S, Grades A or B. Do not use Type F pipe. 2.2.2 Painting for Chilled Water Piping Systems
Prior to installation of piping insulation, clean, pretreat, prime, and paint new chilled water piping systems including valves, piping, conduit, hangers, supports, miscellaneous metalwork, and accessories. Apply coatings to clean, dry surfaces, using clean brushes. Clean the surfaces to remove dust, dirt, rust, and loose mill scale. Immediately after cleaning, provide the metal surfaces with one coat primer. Provide primed surfaces with one coat of white alkyd gloss enamel applied to a minimum dry film thickness of 1.0 mil in attic spaces, spaces above suspended ceilings, crawl spaces, pipe chases, mechanical equipment room, and spaces where walls or ceiling are not painted or not constructed of a prefinished material. 2.2.3 Fittings and End Connections (Joints)
Piping and fittings 1 inch and smaller shall have threaded connections. Piping and fittings larger than 1 inch and smaller than 3 inches shall have either threaded, grooved, or welded connections. Piping and fittings 3 inches and larger shall have grooved, welded, or flanged connections. The manufacturer of each fitting shall be permanently identified on the body of the fitting in accordance with MSS SP-25. 2.2.3.1 Threaded Connections
Use threaded valves and pipe connections conforming to ASME B1.20.1. Used threaded fitting conforming to ASME B16.3. Use threaded unions conforming to ASME B16.39. Use threaded pipe nipples conforming to ASTM A733. 2.2.3.2 Flanged Connections
Flanges shall conform to ASME B16.1, Class 150. Gaskets shall be nonasbestos compressed material in accordance with ASME B16.21, 1/16 inch thickness, full face or self-centering flat ring type. These gaskets shall contain aramid fibers bonded with styrene butadeine rubber (SBR) or nitrile butadeine rubber (NBR). Bolts, nuts, and bolt patterns shall conform to ASME B16.1. 2.2.3.3 Welded Connections
Welded valves and pipe connections (both butt-welds and socket-welds types) shall conform to ASME B31.9. Butt-welded fittings shall conform to ASME B16.9. Socket-welded fittings shall conform to ASME B16.11. Welded fittings shall be identified with the appropriate grade and marking symbol. 2.2.2.4 Grooved Mechanical Connections For Steel
Rigid grooved mechanical connections may only be used in serviceable aboveground locations where the temperature of the circulating medium does not exceed 230 degrees F. Flexible grooved connections shall be used only as a flexible connector with grooved pipe system. Unless otherwise specified, grooved piping components shall meet the corresponding criteria SECTION 23 64 26 Page 9
123044
specified for the similar welded, flanged, or threaded component specified herein. Each grooved mechanical joint shall be a system, including coupling housing, gasket, fasteners, all furnished by the same manufacturer. Joint installation shall be in compliance with joint manufacturer's written instructions. Use fitting and coupling houses of malleable iron conforming to ASTM A47/A47M, Grade 32510; ductile iron conforming to ASTM A536, Grade 65-45-12; or steel conforming ASTM A106/A106M, Grade B or ASTM A53/A53M. Use gaskets of molded synthetic rubber with central cavity, pressure responsive configuration and conforming to ASTM D 2000 Grade No. 2CA615A15B44F17Z for circulating medium up to 230 degrees F or Grade No. M3BA610A15B44Z for circulating medium up to 200 degrees F. Grooved mechanical connections shall conform to AWWA C606. Coupling nuts and bolts shall be steel and shall conform to ASTM A183. Pipe connections and fittings shall be the product of the same manufacturer. Provide joint installation be in compliance with joint manufacturer's written instructions. 2.2.3.4 Dielectric Waterways and Flanges
Provide dielectric waterways with a water impervious insulation barrier capable of limiting galvanic current to 1 percent of short circuit current in a corresponding bimetallic joint. When dry, insulation barrier shall be able to withstand a 600-volt breakdown test. Provide dielectric waterways constructed of galvanized steel and have threaded end connections to match connecting piping. Dielectric waterways shall be suitable for the required operating pressures and temperatures. Provide dielectric flanges with the same pressure ratings as standard flanges and provide complete electrical isolation between connecting pipe and/or equipment as described herein for dielectric waterways. 2.3 COPPER TUBING
Provide copper tubing and fittings with a ANSI/ASME Class 125 service rating, which for 150 degrees F., the pressure rating is 175 psig. 2.3.1 Tube
Use copper tube conforming to ASTM B88, Type L or M for aboveground tubing, and Type K for buried tubing. 2.3.2 Fittings and End Connections (Solder and Flared Joints)
Wrought copper and bronze solder joint pressure fittings, including unions ands flanges, shall conform to ASME B16.22 and ASTM B75. Provide adapters as required. Cast copper alloy solder-joint pressure fittings , including unions and flanges, shall conform to ASME B16.18. Cast copper alloy fittings for flared copper tube shall conform to ASME B16.26 and ASTM B62. ASTM B42 copper pipe nipples with threaded end connections shall conform to ASTM B42. Copper tubing of sizes larger than 4 inches shall have brazed joints.Brass or bronze adapters for brazed tubing may be used for connecting tubing to flanges and to threaded ends of valves and equipment. Extracted brazed tee joints may be used if produced with an acceptable tool SECTION 23 64 26 Page 10
123044
and installed in accordance with tool manufacturer's written procedures. 2.5.3 Grooved Mechanical Connections For Copper
Rigid grooved mechanical connections may only be used in serviceable aboveground locations where the temperature of the circulating medium does not exceed 230 degrees F. Flexible grooved connections shall be used only as a flexible connector with grooved pipe system. Unless otherwise specified, grooved piping components shall meet the corresponding criteria specified for the similar welded, flanged, or threaded component specified herein. Each grooved mechanical joint shall be a system, including coupling housing, gasket, fasteners, all furnished by the same manufacturer. Joint installation shall be in compliance with joint manufacturer's written instructions. Grooved fitting and mechanical coupling housing shall be ductile iron conforming to ASTM A536. Provide gaskets for use in grooved joints shall constructed of molded synthetic polymer of pressure responsive design and shall conform to ASTM D 2000 for circulating medium up to 230 degrees F. Provide grooved joints in conformance with AWWA C606. 2.3.3 Solder
Provide solder in conformance with ASTM B32, grade Sb5, tin-antimony alloy. Solder flux shall be liquid or paste form, non-corrosive and conform to ASTM B813. 2.3.4 Brazing Filler Metal
Filler metal shall conform to AWS A5.8/A5.8M, Type BAg-5 with AWS Type 3 flux, except Type BCuP-5 or BCuP-6 may be used for brazing copper-to-copper joints. 2.4 VALVES
Provide valves with a ANSI/ASME Class 125 service rating, which for 150 degrees F, the pressure rating is 175 psig. Valves in sizes larger than 1 inch and used on steel pipe systems, may be provided with rigid grooved mechanical joint ends. Such grooved end valves shall be subject to the same requirements as rigid grooved mechanical joints and fittings and, shall be furnished by the same manufacturer as the grooved pipe joint and fitting system. 2.4.1 Gate Valve
Gate valves 2-1/2 inches and smaller shall conform to MSS SP-80 Class 125 and shall be bronze with wedge disc, rising stem and threaded, soldered, or flanged ends. Gate valves 3 inches and larger shall conform to MSS SP-70, Class 125, cast iron with bronze trim, outside screw and yoke, and flanged or threaded ends. 2.4.2 Globe and Angle Valve
Globe and angle valves 2-1/2 inches and smaller shall conform to MSS SP-80, Class 125. Globe and angle valves 3 inches and larger shall conform to MSS SP-85, Class 125. SECTION 23 64 26 Page 11
123044
2.4.3
Check Valve Check
Check valves 2-1/2 inches and smaller shall conform to MSS SP-80. valves 3 inches and larger shall conform to MSS SP-71, Class 125. 2.4.4 Butterfly Valve
Butterfly valves shall conform to MSS SP-67, Type 1 and shall be either the wafer or lug type. Valves smaller than 8 inches shall have throttling handles with a minimum of [two][seven] locking positions. Valves 8 inches and larger shall have totally enclosed manual gear operators with adjustable balance return stops and position indicators. 2.4.5 Plug Valve
Plug valves 2 inches and larger shall conform to MSS SP-78, have flanged or threaded ends, and have cast iron bodies with bronze trim. Valves 2 inches and smaller shall be bronze with NPT connections for black steel pipe and brazed connections for copper tubing. Valve shall be lubricated, non-lubricated, or tetrafluoroethylene resin-coated type. Valve shall be resilient, double seated, trunnion mounted with tapered lift plug capable of 2-way shutoff. Valve shall operate from fully open to fully closed by rotation of the handwheel to lift and turn the plug. [Valve shall a weatherproof operators with mechanical position indicators.] Valves 8 inches or larger shall be provided with manual gear operators with position indicators. 2.4.6 Ball Valve
Full port design. Ball valves 1/2 inch and larger shall conform to MSS SP-72 or MSS SP-110 and shall be cast iron or bronze with threaded, soldered, or flanged ends. Valves 8 inches or larger shall be provided with manual gear operators with position indicators. Ball valves may be provided in lieu of gate valves. 2.4.7 Square Head Cocks
Provide copper alloy or cast-iron body with copper alloy plugs, suitable for 125 psig water working pressure. 2.6.8 Calibrated Balancing Valves
Copper alloy or cast iron body, copper alloy or stainless internal working parts. Provide valve calibrated so that flow can be determined when the temperature and pressure differential across valve is known. Valve shall have an integral pointer which registers the degree of valve opening. Valve shall function as a service valve when in fully closed position. Valve shall be constructed with internal seals to prevent leakage and shall be supplied with preformed insulation. Provide valve bodies with tapped openings and pipe extensions with positive shutoff valves outside of pipe insulation. The pipe extensions shall be provided with quick connecting hose fittings for a portable differential pressure meter connections to verify the pressure differential. Provide metal tag on each valve showing the gallons per minute flow for each differential pressure reading. [In lieu of the balancing valve with integral metering connections, a ball valve or plug valve with a separately installed orifice plate or venturi tube may be used for balancing.] SECTION 23 64 26 Page 12
123044
2.6.9
Automatic Flow Control Valves
Valve shall automatically maintain the constant flow indicated on the design drawings. Valve shall modulate by sensing the pressure differential across the valve body. Valve shall be selected for the flow required and provided with a permanent nameplate or tag carrying a permanent record of the factory-determined flow rate and flow control pressure levels. Provide valve that controls the flow within 5 percent of the tag rating. Valve materials shall be the same as specified for the ball or plug valves. Provide valve that are [electric][ or ][pneumatic] type as indicated. Valve shall be capable of positive shutoff against the system pump head, valve bodies shall be provided with tapped openings and pipe extensions with shutoff valves outside of pipe insulation. The pipe extensions shall be provided with quick connecting hose fittings and differential meter, suitable for the operating pressure specified. Provide the meter complete with hoses, vent, integral metering connections, and carrying case as recommended by the valve manufacturer. 2.6.10 Pump Discharge Valve
Valve shall shall perform the functions of a nonslam check valve, a manual balancing valve, and a shutoff. Valve shall be of cast iron or ductile iron construction with bronze and/or stainless steel accessories. Provide an integral pointer on the valve which registers the degree of valve opening. Flow through the valve shall be manually adjustable from bubble tight shutoff to full flow. Valves smaller than 2 inches shall have NPT connections. Valves 2 inches and larger shall have flanged or grooved end connections. Valve design shall allow the back seat for the stem to be replaced in the field under full line pressure. 2.6.11 Water Temperature Mixing Valve
Valve, ASSE 1017 for water service. 2.6.12 Water Temperature Regulating Valves
Provide copper alloy body, direct acting, pilot operated, for the intended service. 2.6.13 Water Pressure Reducing Valve
Valve, ASSE 1003 for water service, copper alloy body, automatic re-seating, with test lever. 2.4.8 Pressure Relief Valve
Valve shall prevent excessive pressure in the piping system when the piping system reaches its maximum heat buildup. Valve, ANSI Z21.22/CSA 4.4 and shall have cast iron bodies with corrosion resistant internal working parts. The discharge pipe from the relief valve shall be the size of the valve outlet unless otherwise indicated. 2.6.15 Combination Pressure and Temperature Relief Valves
ANSI Z21.22/CSA 4.4, copper alloy body, automatic re-seating, test lever, and discharge capacity based on AGA temperature steam rating.
SECTION 23 64 26
Page 13
123044
2.6.16
Float Valve
Valve, CID A-A-50541, [Style A (angle pattern)][ and][or] [Style B (globe pattern)]. Where float rods are extended for tank applications, extension shall be properly supported and guided to avoid bending of float rod or stressing of valve pilot linkage. 2.4.9 Drain Valves
Valves, MSS SP-80 gate valves. Valve shall be manually-operated, 3/4 inch pipe size and above with a threaded end connection. Provide valve with a water hose nipple adapter. [Freeze-proof type valves shall be provided in installations exposed to freezing temperatures.] 2.4.10 Air Venting Valves
[Manually-operated general service type air venting valves, brass or bronze valves that are furnished with threaded plugs or caps.] [Automatic type air venting shall be the ball-float type with brass/bronze or brass bodies, 300 series corrosion-resistant steel float, linkage and removable seat.] Air venting valves on water coils shall have not less than 1/8 inch threaded end connections. Air venting valves on water mains shall have not less than 3/4 inch threaded end connections. Air venting valves on all other applications shall have not less than 1/2 inch threaded end connections. 2.4.11 Vacuum Relief Valves
ANSI Z21.22/CSA 4.4 2.5 2.5.1 PIPING ACCESSORIES Strainer
Strainer, ASTM F 1199, except as modified and supplemented in this specification. Strainer shall be the cleanable, basket or "Y" type, the same size as the pipeline. Strainer bodies shall be fabricated of cast iron with bottoms drilled, and tapped. Provide blowoff outlet with pipe nipple, gate valve, and discharge pipe nipple. The bodies shall have arrows clearly cast on the sides indicating the direction of flow. Provide strainer with removable cover and sediment screen. The screen shall be made of minimum 22 gauge [brass sheet,] [monel,] [corrosion-resistant steel,] with small perforations numbering not less than 400 per square inch to provide a net free area through the basket of at least 3.30 times that of the entering pipe. The flow shall be into the screen and out through the perforations. 2.7.2 Cyclonic Separator
Metal- bodied, with removal capability of removing solids 45 microns/325 mesh in size and heavier than 1.20 specific gravity, maximum pressure drop of 5 psid, with cleanout connection. 2.5.2 Combination Strainer and Pump Suction Diffuser
Angle type body with removable strainer basket and internal straightening vanes, a suction pipe support, and a blowdown outlet and plug. Strainer shall be in accordance with ASTM F 1199, except as modified and SECTION 23 64 26 Page 14
123044
supplemented by this specification. Unit body shall have arrows clearly cast on the sides indicating the direction of flow. Strainer screen shall be made of minimum 22 gauge [brass sheet,] [monel,] [corrosion-resistant steel,] with small perforations numbering not less than 400 per square inch to provide a net free area through the basket of at least 3.30 times that of the entering pipe. Flow shall be into the screen and out through the perforations. Provide an auxiliary disposable fine mesh strainer which shall be removed 30 days after start-up. Provide warning tag for operator indicating scheduled date for removal. Casing shall have connection sizes to match pump suction and pipe sizes, and be provided with adjustable support foot or support foot boss to relieve piping strains at pump suction. Provide unit casing with blowdown port and plug. Provide a magnetic insert to remove debris from system. 2.5.3 Flexible Pipe Connectors
Provide flexible bronze or stainless steel piping connectors with single braid. Equip flanged assemblies with limit bolts to restrict maximum travel to the manufacturer's standard limits. Unless otherwise indicated, the length of the flexible connectors shall be as recommended by the manufacturer for the service intended. Internal sleeves or liners, compatible with circulating medium, shall be provided when recommended by the manufacturer. Provide covers to protect the bellows where indicated. 2.5.4 Pressure and Vacuum Gauges
Gauges, ASME B40.100 with throttling type needle valve or a pulsation dampener and shut-off valve. Provide gauges with 4.5 inch dial, brass or aluminum case, bronze tube, and siphon. Gauge shall have a minimum of with a range from 0 psig to approximately 1.5 times the maximum system working pressure. Each gauge range shall be selected so that at normal operating pressure, the needle is within the middle-third of the range. 2.5.5 Temperature Gauges
Temperature gauges, shall be the industrial duty type and be provided for the required temperature range. Provide gauges with fixed thread connection, dial face gasketed within the case; and an accuracy within 2 percent of scale range. Gauges shall have Fahrenheit scale in 2 degree graduations scale (black numbers) on a white face. The pointer shall be adjustable. Rigid stem type temperature gauges shall be provided in thermal wells located within 5 feet of the finished floor. Universal adjustable angle type or remote element type temperature gauges shall be provided in thermal wells located 5 to 7 feet above the finished floor or in locations indicated. Remote element type temperature gauges shall be provided in thermal wells located 7 feet above the finished floor or in locations indicated. 2.5.5.1 Stem Cased-Glass
Stem cased-glass case shall be polished stainless steel or cast aluminum, 9 inches long, with clear acrylic lens, and non-mercury filled glass tube with indicating-fluid column. 2.5.5.2 Bimetallic Dial
Bimetallic dial type case shall be not less than 3-1/2 inches, stainless SECTION 23 64 26 Page 15
123044
steel, and shall be hermetically sealed with clear acrylic lens. Bimetallic element shall be silicone dampened and unit fitted with external calibrator adjustment. 2.5.5.3 Liquid-, Solid-, and Vapor-Filled Dial
Liquid-, solid-, and vapor-filled dial type cases shall be not less than 3-1/2 inches, stainless steel or cast aluminum with clear acrylic lens. Fill shall be nonmercury, suitable for encountered cross-ambients, and connecting capillary tubing shall be double-braided bronze. 2.5.5.4 Thermal Well
Thermal well shall be identical size, 1/2 or 3/4 inch NPT connection, brass or stainless steel. Where test wells are indicated, provide captive plug-fitted type 1/2 inch NPT connection suitable for use with either engraved stem or standard separable socket thermometer or thermostat. Mercury shall not be used in thermometers. Extended neck thermal wells shall be of sufficient length to clear insulation thickness by 1 inch. 2.5.6 Pipe Hangers, Inserts, and Supports to MSS SP-58 and MSS SP-69.
Pipe hangers, inserts, guides, and supports: 2.5.7 Escutcheons
Provide one piece or split hinge metal plates for piping entering floors, walls, and ceilings in exposed spaces. Secure plates in place by internal spring tension or set screws. Provide polished stainless steel plates or chromium-plated finish on copper alloy plates in finished spaces. Provide paint finish on metal plates in unfinished spaces. 2.5.8 2.7.9.1 Expansion Joints Slip-Tube Type
Slip-tube expansion joints, ASTM F 1007, Class I or II. Joints shall be provided with internally-externally alignment guides, injected semi-plastic packing, and service outlets. End connections shall be flanged or beveled for welding as indicated. Initial settings shall be made in accordance with the manufacturer's recommendations to compensate for ambient temperature at time of installation. Pipe alignment guides shall be installed as recommended by the joint manufacturer. 2.7.9.2 Flexible Ball Type
Flexible ball expansion joints shall be capable of 360 degrees rotation plus 15 degrees angular flex movement. Joints shall be constructed of carbon steel with the exterior spherical surface of carbon steel balls plated with a minimum 5 mils of hard chrome in accordance with EJMA Stds. Joint end connections shall be threaded for piping 2 inches or smaller. Joint end connections larger than 2 inches shall be grooved, flanged, or beveled for welding. Provide joint with pressure-molded composition gaskets suitable for continuous operation at twice design temperature. 2.5.8.1 BellowsFlexible Loop Type
Bellows expansion type joints, ASTM F 1120 with Type 304 stainless steel corrugated bellows, reinforced with equalizing rings, internal sleeves, and SECTION 23 64 26 Page 16
123044
external protective covers. Joint end connections shall be grooved, flanged, or beveled for welding. Guiding of piping on both sides of expansion joint shall be in accordance with the published recommendations of the manufacturer of the expansion joint.Provide flexible expansion loops of the size and type indicated on the drawings. Flexible loops shall consist of two flexible sections of hose and braid, two, 90 degree elbows, and an 180 degree return assembled in such a way that the piping does not change direction, but maintains its course along a single axis. Flexible loops shall have a factory supplied, center support nut located at the bottom of the 180 degree return, and a drain/air release plug. Flexible loops shall impart no thrust loads to system support anchors or building structure. Loops shall be instaled in a neutral, pre-extended condition as required for the application. Install and guide in accordance with manufacturer's recommendations. Materials of construciton and end fitting type shall eb consistent with pipe material and equipment/pipe connections fittings. Braided hose section shall consist of carbon steel, copper or stainless steel ends, connecting braze or weldment, and connection shall be encased in a stress releiveing weld collar. Hose shall be stainless steel or bronze flexible metallic hose encased in a stainless steel or bronze braid. Rubber hose materials are prohibited. 2.6 PUMPS
Pumps shall be the electrically driven, non-overloading, centrifugal type which conform to HI 1.1-1.2. Pumps shall be selected at or within 5 percent of peak efficiency. Pump curve shall rise continuously from maximum capacity to shutoff. Pump motor shall conform to NEMA MG 1, be [open] [splash-proof] [totally enclosed], and have sufficient horsepower for the service required. Pump motor shall have the required capacity to prevent overloading with pump operating at any point on its characteristic curve. Pump speed shall not exceed 3,600 rpm, except where the pump head is less than 60 feet of water, the pump speed shall not exceed 1,750 rpm. Pump motor shall be equipped with an across-the-line magnetic controller in a NEMA 250, Type 1 enclosure with "START-STOP" switch in the cover. 2.6.1 Construction
Each pump casing shall be designed to withstand the discharge head specified plus the static head on system plus 50 percent of the total, but not less than 125 psig. Pump casing and bearing housing shall be close grained cast iron. High points in the casing shall be provided with manual air vents; low points shall be provided with drain plugs. Provide threaded suction and discharge pressure gage tapping with square-head plugs. Impeller shall be statically and dynamically balanced. Impeller, impeller wearing rings, glands, casing wear rings, and shaft sleeve shall be bronze. Shaft shall be carbon or alloy steel, turned and ground. Bearings shall be ball-bearings, roller-bearings, or oil-lubricated bronze-sleeve type bearings, and be efficiently sealed or isolated to prevent loss of oil or entrance of dirt or water. [Pump and motor shall be mounted on a common cast iron base having lipped edges and tapped drainage openings or structural steel base with lipped edges or drain pan and tapped drainage openings.Pump shall be provided with steel shaft coupling guard. Base-mounted pump, coupling guard, and motor shall each be bolted to a fabricated steel base which shall have bolt holes for securing base to supporting surface.] [Close-coupled pump shall be provided with integrally cast or fabricated steel feet with bolt holes for securing feet to supporting surface. Close- coupled pumps shall be provided SECTION 23 64 26 Page 17
123044
with drip pockets and tapped openings.] Pump shall be accessible for servicing without disturbing piping connections. Shaft seals shall be mechanical-seals or stuffing-box type. 2.6.2 Mechanical Shaft Seals
Seals shall be single, inside mounted, end-face-elastomer bellows type with stainless steel spring, brass or stainless steel seal head, carbon rotating face, and tungsten carbide or ceramic sealing face. Glands shall be bronze and of the water-flush design to provide lubrication flush across the face of the seal. Bypass line from pump discharge to flush connection in gland shall be provided, with filter or cyclone particle separator in line. 2.8.3 Stuffing-Box Type Seals
Stuffing box shall include minimum 4 rows of square, impregnated TFE (Teflon) or graphite cord packing and a bronze split-lantern ring. Packing gland shall be bronze interlocking split type. 2.7 EXPANSION TANKS
Tank shall be welded steel, constructed for, and tested to pressure-temperature rating of 125 psi at 150 degrees F. Provide tanks precharged to the minimum operating pressure. Tank shall have a replaceable polypropylene or butyl lined diaphragm which keeps the air charge separated from the water; shall be the captive air type. Tanks shall accommodate expanded water of the system generated within the normal operating temperature range, limiting this pressure increase at all components in the system to the maximum allowable pressure at those components. Each tank air chamber shall be fitted with a drain, fill, an air charging valve, and system connections. Tank shall be supported by steel legs or bases for vertical installation or steel saddles for horizontal installations. The only air in the system shall be the permanent sealed-in air cushion contained within the expansion tank. 2.8 AIR SEPARATOR TANKS
[External air separation tank shall have an internal design constructed of stainless steel and suitable for creating the required vortex and subsequent air separation. Tank shall be steel, constructed for, and tested to pressure-temperature rating of 125 psi at 150 degrees F. Tank shall have tangential inlets and outlets connections, threaded for 2 inches and smaller and flanged for sizes 2-1/2 inches and larger. Air released from a tank shall be [to the atmosphere] [vented as indicated]. Tank shall be provided with a blow-down connection.] [Design to separate air from water and to direct released air to automatic air vent. Unit shall be of one piece cast-iron construction with internal baffles and two air chambers at top of unit; one air chamber shall have outlet to expansion tank and other air chamber shall be provided with automatic air release device. Tank shall be steel, constructed for, and tested to a ANSI Class 125 pressure-temperature rating.] 2.9 CHILLED WATER BUFFER TANKS
Chilled water buffer tank shall be ASME Code constructed and stamped in accordance with ASME BPVC SEC VIII of the ASME Code. Tank shall be registered with the National Board of Boiler and Pressure Vessel Inspectors SECTION 23 64 26 Page 18
123044
and a certificate of shop inspection shall be furnished. ASME working pressure shall be 125 psi. Material of construction shall be Carbon Steel. Vessels above 42" in diameter shall be furnished with a 12" x 16" manhole. Tank shall be furnished with an air vent, a 1/2" flexible, elastomeric thermal insulation black in color, and internal baffle to divert water flow. 2.10 ELECTRICAL HEAT TRACING
Heat trace systems for pipes, valves, and fittings shall be in accordance with IEEE 515 and be UL listed. System shall include all necessary components, including heaters and controls to prevent freezing. Provide self-regulating heaters consisting of two 16 AWG tinned-copper bus wires embedded in parallel in a self-regulating polymer core that varies its power output to respond to temperature along its length. Heater shall be able to be crossed over itself without overheating. Heater shall be covered by a radiation cross-linked modified polyolefin dielectric jacket in accordance with ASTM D 2308. Provide heater with self-regulating factor of at least 90 percent, in order to provide energy conservation and to prevent overheating. Heater shall operate on line voltages of 120 volts without the use of transformers. Size Heat Tracing according to the following table:
Pipe Size (Inch, Diameter) 3 inches or less 4 inch 6 inch
Minus 10 degrees F 5 watts per foot (wpf) 5 wpf 8 wpf
Minus 20 degrees F 5 wpf 8 wpf 8 wpf
System shall be controlled by an ambient sensing thermostat set at 40 degrees F either directly or through an appropriate contactor. 2.11 WATER TREATMENT SYSTEMS
When water treatment is specified, the use of chemical-treatment products containing equivalent chromium (CPR) is prohibited. 2.11.1 Water Analysis
Conditions of make-up water to be supplied to the condenser and chilled water systems were reported in accordance with ASTM D 596 and are as follows:
Date of Sample Temperature Silica (Sino 2) Insoluble Iron and Aluminum Oxides Calcium (Ca) Magnesium (Mg) Sodium and Potassium (Nan and AK) SECTION 23 64 26 Page 19
[_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____]
degrees F. pp (mg/1) pp (mg/1) pp (mg/1) pp (mg/1) pp (mg/1) pp (mg/1)
123044
Carbonate (HO 3) Sulfate (SO 4) Chloride (JCL) Nitrate (NO 3) Turbidity pH Residual Chlorine Total Alkalinity Non-Carbonate Hardness Total Hardness Dissolved Solids Fluorine Conductivity 2.11.2 Chilled and Condenser Water
[_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____]
pp (mg/1) pp (mg/1) pp (mg/1) pp (mg/1) unit pp (mg/1) PM (me/1) PM (me/1) PM (me/1) pp (mg/1) pp (mg/1) McMahon/cm
Water to be used in the chilled and condenser water systems shall be treated to maintain the conditions recommended by this specification as well as the recommendations from the manufacturers of the condenser and evaporator coils. Chemicals shall meet all required federal, state, and local environmental regulations for the treatment of evaporator coils and direct discharge to the sanitary sewer. 2.11.3 Glycol Solution
A [_____] percent concentration by volume of industrial grade [ethylene] [propylene] glycol shall be provided in the chilled water. The glycol shall be tested in accordance with ASTM D 1384 with less than 0.5 mils penetration per year for all system metals. The glycol shall contain corrosion inhibitors. Silicate based inhibitors shall not be used. The solution shall be compatible with pump seals, other elements of the system, and water treatment chemicals used within the system. 2.11.4 Water Treatment Services
The services of a company regularly engaged in the treatment of [condenser] [condenser and chilled] water systems shall be used to determine the correct chemicals required, the concentrations required, and the water treatment equipment sizes and flow rates required. The company shall maintain the chemical treatment and provide all chemicals required for the [condenser] [condenser and chilled] water systems for a period of 1 year from the date of occupancy. The chemical treatment and services provided over the 1 year period shall meet the requirements of this specification as well as the recommendations from the manufacturers of the condenser and evaporator coils. Acid treatment and proprietary chemicals shall not be used. 2.11.5 Chilled Water System
A shot feeder shall be provided on the chilled water piping as indicated. Size and capacity of feeder shall be based on local requirements and water analysis. The feeder shall be furnished with an air vent, gauge glass, funnel, valves, fittings, and piping. 2.11.6 Condenser Water
The water treatment system shall be capable of [automatically] [continuously] feeding chemicals and bleeding the system to prevent corrosion, scale, and biological formations. [Automatic chemical feed SECTION 23 64 26 Page 20
123044
systems shall automatically feed chemicals into the condenser water based on varying system conditions.] [Continuous chemical feed systems shall continuously feed chemicals into the condenser water at a constant rate. The system shall be initially set manually based on the water analysis of the make-up water.] 2.11.6.1 Chemical Feed Pump
One pump shall be provided for each chemical feed tank. The chemical feed pumps shall be positive displacement diaphragm type. The flow rate of the pumps shall be adjustable from 0 to 100 percent while in operation. The discharge pressure of pumps shall not be less than 1.5 times the line pressure at the point of connection. The pumps shall be provided with a pressure relief valve and a check valve mounted in the pump discharge. 2.11.6.2 Tanks
Two chemical tanks shall be provided. The tanks shall be constructed of [high density polyethylene] [stainless steel] with a hinged cover. The tanks shall have sufficient capacity to require recharging only once per 7 days during normal operation. A level indicating device shall be included with each tank. An electric agitator shall be provided for each tank. 2.11.6.3 Injection Assembly
An injection assembly shall be provided at each chemical injection point along the condenser water piping as indicated. The injection assemblies shall be constructed of stainless steel. The discharge of the assemblies shall extend to the centerline of the condenser water piping. Each assembly shall include a shutoff valve and check valve at the point of entrance into the condenser water line. 2.11.6.4 Water Meter
Water meters shall be provided with an electric contacting register and remote accumulative counter. The meter shall be installed within the make-up water line, as indicated. 2.11.6.5 Timers
Timers shall be of the automatic reset, adjustable type, and electrically operated. The timers shall be suitable for a 120 volt current. The timers shall be located within the water treatment control panel. 2.11.6.6 Water Treatment Control Panel
The control panel shall be a NEMA 12 enclosure suitable for surface mounting. The panel shall be constructed of [stainless steel] [steel] with a hinged door and lock. The panel shall contain a laminated plastic nameplate identifying each of the following functions: (1) (2) (3) (4) (5) Main power switch and indicating light MAN-OFF-AUTO selector switch Indicating lamp for bleed-off valve Indicating lamp for each chemical feed pump Set point reading for each timer
SECTION 23 64 26
Page 21
123044
2.11.6.7
Chemical Piping
The piping and fittings shall be constructed of [schedule 80 PVC] [stainless steel] suitable for the water treatment chemicals. 2.11.6.8 Sequence of Operation
[The chemicals shall be added based upon sensing the make-up water flow rate and activating appropriate timers. A separate timer shall be provided for each chemical. The blow down shall be controlled based upon the make-up water flow rate and a separate timer.] [The system shall contain an adjustable valve for continuous blow down. The flow rate from the appropriate chemical tanks shall be manually set at the metering pump for continuous chemical feed.] The injection of the chemical required for biological control shall be controlled by a timer which can be manually set for proper chemical feed. Timer set points, blow down rates, and chemical pump flow rates shall be determined and set by the water treatment company. 2.11.6.9 Test Kits
One test kit of each type required to determine the water quality as outlined within the operation and maintenance manuals shall be provided. 2.11.6.10 Bleed Line
A bleed line with a flow valve of the needle-valve type sized for the flow requirement or fixed orifice shall be provided in the pump return to the tower. The bleed line shall be extended to the nearest drain for continuous discharge. 2.11 ELECTRICAL WORK
Provide motors, controllers, integral disconnects, contactors, and controls with their respective pieces of equipment, except controllers indicated as part of motor control centers. Provide electrical equipment, including motors and wiring, as specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Manual or automatic control and protective or signal devices required for the operation specified and control wiring required for controls and devices specified, but not shown, shall be provided. For packaged equipment, the manufacturer shall provide controllers including the required monitors and timed restart. Provide high efficiency type, single-phase, fractional-horsepower alternating-current motors, including motors that are part of a system, in accordance with NEMA MG 11. Provide polyphase, squirrel-cage medium induction motors, including motors that are part of a system, that meet the efficiency ratings for premium efficiency motors in accordance with NEMA MG 1. Provide motors in accordance with NEMA MG 1 and of sufficient size to drive the load at the specified capacity without exceeding the nameplate rating of the motor. Motors shall be rated for continuous duty with the enclosure specified. Motor duty requirements shall allow for maximum frequency start-stop operation and minimum encountered interval between start and stop. Motor torque shall be capable of accelerating the connected load within 20 seconds with 80 percent of the rated voltage maintained at motor terminals during one starting period. Provide motor starters complete with thermal overload protection and other necessary appurtenances. Motor bearings SECTION 23 64 26 Page 22
123044
shall be fitted with grease supply fittings and grease relief to outside of the enclosure. [Where two-speed or variable-speed motors are indicated, solid-state variable-speed controllers may be provided to accomplish the same function. Use solid-state variable-speed controllers for motors rated 10 hp or less and adjustable frequency drives for larger motors.] [Provide variable frequency drives for motors as specified in Section 26 29 23 VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600 VOLTS.] 2.12 PAINTING OF NEW EQUIPMENT
New equipment painting shall be factory applied or shop applied, and shall be as specified herein, and provided under each individual section. 2.12.1 Factory Painting Systems
Manufacturer's standard factory painting systems may be provided. The factory painting system applied will withstand 125 hours in a salt-spray fog test, except that equipment located outdoors shall withstand 500 hours in a salt-spray fog test. Salt-spray fog test shall be in accordance with ASTM B117, and for that test, the acceptance criteria shall be as follows: immediately after completion of the test, the paint shall show no signs of blistering, wrinkling, or cracking, and no loss of 0.125 inch on either side of the scratch mark. The film thickness of the factory painting system applied on the equipment shall not be less than the film thickness used on the test specimen. If manufacturer's standard factory painting system is being proposed for use on surfaces subject to temperatures above 120 degrees F, the factory painting system shall be designed for the temperature service. 2.12.2 Shop Painting Systems for Metal Surfaces
Clean, retreat, prime and paint metal surfaces; except aluminum surfaces need not be painted. Apply coatings to clean dry surfaces. Clean the surfaces to remove dust, dirt, rust, oil and grease by wire brushing and solvent degreasing prior to application of paint, except metal surfaces subject to temperatures in excess of 120 degrees F shall be cleaned to bare metal. Where hot-dip galvanized steel has been cut, resulting surfaces with no galvanizing shall be coated with a zinc-rich coating conforming to ASTM D 520, Type I. Where more than one coat of paint is specified, apply the second coat after the preceding coat is thoroughly dry. Lightly sand damaged painting and retouch before applying the succeeding coat. Color of finish coat shall be aluminum or light gray. a. Temperatures Less Than 120 Degrees F: Immediately after cleaning, the metal surfaces subject to temperatures less than 120 degrees F shall receive one coat of pretreatment primer applied to a minimum dry film thickness of 0.3 mil, one coat of primer applied to a minimum dry film thickness of one mil; and two coats of enamel applied to a minimum dry film thickness of one mil per coat.
SECTION 23 64 26
Page 23
123044
b.
Temperatures Between 120 and 400 degrees F: Metal surfaces subject to temperatures between 120 and 400 degrees F shall receive two coats of 400 degrees F heat-resisting enamel applied to a total minimum thickness of 2 mils. Temperatures Greater Than 400 degrees F: Metal surfaces subject to temperatures greater than 400 degrees F shall receive two coats of 600 degrees F heat-resisting paint applied to a total minimum dry film thickness of 2 mils. FACTORY APPLIED INSULATION
c.
2.13
Factory insulated items installed outdoors are not required to be fire-rated. As a minimum, factory insulated items installed indoors shall have a flame spread index no higher than 75 and a smoke developed index no higher than 150. Factory insulated items (no jacket) installed indoors and which are located in air plenums, in ceiling spaces, and in attic spaces shall have a flame spread index no higher than 25 and a smoke developed index no higher than 50. Flame spread and smoke developed indexes shall be determined by ASTM E 84. Insulation shall be tested in the same density and installed thickness as the material to be used in the actual construction. Material supplied by a manufacturer with a jacket shall be tested as a composite material. Jackets, facings, and adhesives shall have a flame spread index no higher than 25 and a smoke developed index no higher than 50 when tested in accordance with ASTM E 84. 2.14 NAMEPLATES
Major equipment including pumps, pump motors, expansion tanks, and air separator tanks shall have the manufacturer's name, type or style, model or serial number on a plate secured to the item of equipment. The nameplate of the distributing agent will not be acceptable. Plates shall be durable and legible throughout equipment life and made of [anodized aluminum ][stainless steel][_____]. Plates shall be fixed in prominent locations with nonferrous screws or bolts. 2.15 2.15.1 RELATED COMPONENTS/SERVICES Drain and Make-Up Water Piping
Requirements for drain and make-up water piping and backflow preventer is specified in Section 22 00 00 PLUMBING, GENERAL PURPOSE. 2.16.2 Cathodic Protection
Requirements for cathodic protection systems is specified in [Section 26 42 14.00 10 CATHODIC PROTECTION SYSTEM (SACRIFICIAL ANODE)] [Section 26 42 13.00 20 CATHODIC PROTECTION BY GALVANIC ANODES][and] [Section 26 42 17.00 10 CATHODIC PROTECTION SYSTEM (IMPRESSED CURRENT)][Section 26 42 19.00 20 CATHODIC PROTECTION BY IMPRESSED CURRENT]. 2.15.2 Field Applied Insulation
Requirements for field applied insulation is specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS.
SECTION 23 64 26
Page 24
123044
2.16.4
Field Applied Insulation
Requirements for field installed insulation is specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS, except as supplemented and modified by this specification section. 2.15.3 Field Painting
Requirements for painting of surfaces not otherwise specified, and finish painting of items only primed at the factory, are specified in Section 09 90 00 PAINTS AND COATINGS. [2.15.3.1 Color Coding
Requirements for color coding for piping identification are specified in Section 09 90 00 PAINTS AND COATINGS. ][2.16.5.2 Color Coding For Hidden Piping
A color coding scheme for locating hidden piping shall be in accordance with [Section 22 00 00 PLUMBING, GENERAL PURPOSE] [Section 22 00 70 PLUMBING, HEALTHCARE FACILITIES]. ]PART 3 3.1 EXECUTION
INSTALLATION
Cut pipe accurately to measurements established at the jobsite, and work into place without springing or forcing, completely clearing all windows, doors, and other openings. Cutting or other weakening of the building structure to facilitate piping installation is not permitted without written approval. Cut pipe or tubing square, remove burrs by reaming, and fashion to permit free expansion and contraction without causing damage to the building structure, pipe, joints, or hangers. Notify the Contracting Officer in writing at least 15 calendar days prior to the date the connections are required. Obtain approval before interrupting service. Furnish materials required to make connections into existing systems and perform excavating, backfilling, compacting, and other incidental labor as required. Furnish labor and tools for making actual connections to existing systems. 3.1.1 Welding
Provide welding work specified this section for piping systems in conformance with ASME B31.9, as modified and supplemented by this specification section and the accompanying drawings. The welding work includes: qualification of welding procedures, welders, welding operators, brazers, brazing operators, and nondestructive examination personnel; maintenance of welding records, and examination methods for welds. 3.1.1.1 Employer's Record Documents (For Welding)
Submit for review and approval the following documentation. This documentation and the subject qualifications shall be in compliance with ASME B31.9. a. List of qualified welding procedures that is proposed to be used to provide the work specified in this specification section. SECTION 23 64 26 Page 25
123044
b.
List of qualified welders, brazers, welding operators, and brazing operators that are proposed to be used to provide the work specified in this specification section. List of qualified weld examination personnel that are proposed to be used to provide the work specified in this specification section. Welding Procedures and Qualifications
c.
3.1.1.2 a.
Specifications and Test Results: Submit copies of the welding procedures specifications and procedure qualification test results for each type of welding required. Approval of any procedure does not relieve the Contractor of the responsibility for producing acceptable welds. Submit this information on the forms printed in ASME BPVC SEC IX or their equivalent. Certification: Before assigning welders or welding operators to the work, submit a list of qualified welders, together with data and certification that each individual is performance qualified as specified. Do not start welding work prior to submitting welder, and welding operator qualifications. The certification shall state the type of welding and positions for which each is qualified, the code and procedure under which each is qualified, date qualified, and the firm and individual certifying the qualification tests. Examination of Piping Welds and brazing and ASME B31.9. NDE only. Submit a in ASME B31.9.
b.
3.1.1.3
Conduct non-destructive examinations (NDE) on piping welds verify the work meets the acceptance criteria specified in on piping welds covered by ASME B31.9 is visual inspection piping welds NDE report meeting the requirements specified 3.1.1.4 Welding Safety
Welding and cutting safety requirements shall be in accordance with AWS Z49.1. 3.1.2 Directional Changes
Make changes in direction with fittings, except that bending of pipe 4 inches and smaller is permitted, provided a pipe bender is used and wide weep bends are formed. Mitering or notching pipe or other similar construction to form elbows or tees is not permitted. The centerline radius of bends shall not be less than 6 diameters of the pipe. Bent pipe showing kinks, wrinkles, flattening, or other malformations is not acceptable. 3.1.3 Functional Requirements
Pitch horizontal supply mains down in the direction of flow as indicated. The grade shall not be less than 1 inch in 40 feet. Reducing fittings shall be used for changes in pipe sizes. Cap or plug open ends of pipelines and equipment during installation to keep dirt or other foreign materials out of the system. Pipe not otherwise specified shall be uncoated. Connections to appliances shall be made with malleable iron unions for steel pipe 2-1/2 inches or less in diameter, and with flanges for pipe 3 inches and above in SECTION 23 64 26 Page 26
123044
diameter. Connections between ferrous and copper piping shall be electrically isolated from each other with dielectric waterways or flanges. Piping located in air plenums shall conform to NFPA 90A requirements. Pipe and fittings installed in inaccessible conduits or trenches under concrete floor slabs shall be welded. Equipment and piping arrangements shall fit into space allotted and allow adequate acceptable clearances for installation, replacement, entry, servicing, and maintenance. Electric isolation fittings shall be provided between dissimilar metals. 3.1.4 3.1.4.1 Fittings and End Connections Threaded Connections
Threaded connections shall be made with tapered threads and made tight with PTFE tape complying with ASTM D 3308 or equivalent thread-joint compound applied to the male threads only. Not more than three threads shall show after the joint is made. 3.1.4.2 Brazed Connections
Brazing, AWS BRH, except as modified herein. During brazing, the pipe and fittings shall be filled with a pressure regulated inert gas, such as nitrogen, to prevent the formation of scale. Before brazing copper joints, both the outside of the tube and the inside of the fitting shall be cleaned with a wire fitting brush until the entire joint surface is bright and clean. Do not use brazing flux. Surplus brazing material shall be removed at all joints. Steel tubing joints shall be made in accordance with the manufacturer's recommendations. Piping shall be supported prior to brazing and not be sprung or forced. 3.1.4.3 Welded Connections
Branch connections shall be made with welding tees or forged welding branch outlets. Pipe shall be thoroughly cleaned of all scale and foreign matter before the piping is assembled. During welding, the pipe and fittings shall be filled with an inert gas, such as nitrogen, to prevent the formation of scale. Beveling, alignment, heat treatment, and inspection of weld shall conform to ASME B31.9. Weld defects shall be removed and rewelded at no additional cost to the Government. Electrodes shall be stored and dried in accordance with AWS D1.1/D1.1M or as recommended by the manufacturer. Electrodes that have been wetted or that have lost any of their coating shall not be used. 3.1.4.4 Grooved Mechanical Connections
Prepare grooves in accordance with the coupling manufacturer's instructions. Pipe and groove dimensions shall comply with the tolerances specified by the coupling manufacturer. The diameter of grooves made in the field shall be measured using a "go/no-go" gauge, vernier or dial caliper, or narrow-land micrometer, or other method specifically approved by the coupling manufacturer for the intended application. Groove width and dimension of groove from end of pipe shall be measured and recorded for each change in grooving tool setup to verify compliance with coupling manufacturer's tolerances. Grooved joints shall not be used in concealed locations, such as behind solid walls or ceilings, unless an access panel is shown on the drawings for servicing or adjusting the joint.
SECTION 23 64 26
Page 27
123044
3.1.4.4
Flared Connections
When flared connections are used, a suitable lubricant shall be used between the back of the flare and the nut in order to avoid tearing the flare while tightening the nut. 3.1.4.5 Flanges and Unions
Except where copper tubing is used, union or flanged joints shall be provided in each line immediately preceding the connection to each piece of equipment or material requiring maintenance such as coils, pumps, control valves, and other similar items. Flanged joints shall be assembled square end tight with matched flanges, gaskets, and bolts. Gaskets shall be suitable for the intended application. 3.1.5 Valves
Isolation gate or ball valves shall be installed on each side of each piece of equipment, at the midpoint of all looped mains, and at any other points indicated or required for draining, isolating, or sectionalizing purpose. Isolation valves may be omitted where balancing cocks are installed to provide both balancing and isolation functions. Each valve except check valves shall be identified. Valves in horizontal lines shall be installed with stems horizontal or above. 3.1.6 Air Vents
Air vents shall be provided at all high points, on all water coils, and where indicated to ensure adequate venting of the piping system. 3.1.7 Drains
Drains shall be provided at all low points and where indicated to ensure complete drainage of the piping. Drains shall be accessible, and shall consist of nipples and caps or plugged tees unless otherwise indicated. 3.1.8 Flexible Pipe Connectors
Connectors shall be attached to components in strict accordance with the latest printed instructions of the manufacturer to ensure a vapor tight joint. Hangers, when required to suspend the connectors, shall be of the type recommended by the flexible pipe connector manufacturer and shall be provided at the intervals recommended. 3.1.9 Temperature Gauges
Temperature gauges shall be located on coolant supply and return piping at each heat exchanger, on condenser water piping entering and leaving a condenser, at each automatic temperature control device without an integral thermometer, and where indicated or required for proper operation of equipment. Thermal wells for insertion thermometers and thermostats shall extend beyond thermal insulation surface not less than 1 inch. 3.1.10 Pipe Hangers, Inserts, and Supports supports shall conform to MSS SP-58 and MSS SP-69, modified in this specification section. Pipe shall not be used. Hangers used to support shall be fabricated to permit adequate Page 28
Pipe hangers, inserts, and except as supplemented and hanger types 5, 12, and 26 piping 2 inches and larger
SECTION 23 64 26
123044
adjustment after erection while still supporting the load. Piping subjected to vertical movement, when operating temperatures exceed ambient temperatures, shall be supported by variable spring hangers and supports or by constant support hangers. 3.1.10.1 Hangers
Type 3 shall not be used on insulated piping. Type 24 may be used only on trapeze hanger systems or on fabricated frames. 3.1.10.2 Inserts
Type 18 inserts shall be secured to concrete forms before concrete is placed. Continuous inserts which allow more adjustments may be used if they otherwise meet the requirements for Type 18 inserts. 3.1.10.3 C-Clamps
Type 19 and 23 C-clamps shall be torqued per MSS SP-69 and have both locknuts and retaining devices, furnished by the manufacturer. Field-fabricated C-clamp bodies or retaining devices are not acceptable. 3.1.10.4 Angle Attachments
Type 20 attachments used on angles and channels shall be furnished with an added malleable-iron heel plate or adapter. 3.1.10.5 Saddles and Shields
Where Type 39 saddle or Type 40 shield are permitted for a particular pipe attachment application, the Type 39 saddle, connected to the pipe, shall be used on all pipe 4 inches and larger when the temperature of the medium is 60 degrees F or higher. Type 40 shields shall be used on all piping less than 4 inches and all piping 4 inches and larger carrying medium less than 60 degrees F. A high density insulation insert of cellular glass shall be used under the Type 40 shield for piping 2 inches and larger. 3.1.10.6 Horizontal Pipe Supports
Horizontal pipe supports shall be spaced as specified in MSS SP-69 and a support shall be installed not over 1 foot from the pipe fitting joint at each change in direction of the piping. Pipe supports shall be spaced not over 5 feet apart at valves. [Pipe hanger loads suspended from steel joist with hanger loads between panel points in excess of 50 pounds shall have the excess hanger loads suspended from panel points.] 3.1.10.7 Vertical Pipe Supports
Vertical pipe shall be supported at each floor, except at slab-on-grade, and at intervals of not more than 15 feet, not more than 8 feet from end of risers, and at vent terminations. 3.1.10.8 Pipe Guides
Type 35 guides using, steel, reinforced polytetrafluoroethylene (PTFE) or graphite slides shall be provided where required to allow longitudinal pipe movement. Lateral restraints shall be provided as required. Slide materials shall be suitable for the system operating temperatures, atmospheric conditions, and bearing loads encountered. SECTION 23 64 26 Page 29
123044
3.1.10.9
Steel Slides
Where steel slides do not require provisions for restraint of lateral movement, an alternate guide method may be used. On piping 4 inches and larger, a Type 39 saddle shall be used. On piping under 4 inches, a Type 40 protection shield may be attached to the pipe or insulation and freely rest on a steel slide plate. 3.1.10.10 Multiple Pipe Runs
In the support of multiple pipe runs on a common base member, a clip or clamp shall be used where each pipe crosses the base support member. Spacing of the base support members shall not exceed the hanger and support spacing required for an individual pipe in the multiple pipe run. 3.1.10.11 Seismic Requirements
Piping and attached valves shall be supported and braced to resist seismic loads as specified under Sections 23 05 48.00 4013 48 00 VIBRATION AND SEISMIC PROTECTION FOR MISCELLANEOUS EQUIPMENTCONTROLS FOR HVAC PIPING AND EQUIPMENT. and 13 48 00.00 10 SEISMIC PROTECTION FOR MECHANICAL EQUIPMENT [as shown on the drawings]. Structural steel required for reinforcement to properly support piping, headers, and equipment but not shown shall be provided under this section. Material used for support shall be as specified under Section 05 12 00 STRUCTURAL STEEL. 3.1.10.12 Structural Attachments
Attachment to building structure concrete and masonry shall be by cast-in concrete inserts, built-in anchors, or masonry anchor devices. Inserts and anchors shall be applied with a safety factor not less than 5. Supports shall not be attached to metal decking. Supports shall not be attached to the underside of concrete filled floors or concrete roof decks unless approved by the Contracting Officer. Masonry anchors for overhead applications shall be constructed of ferrous materials only. Structural steel brackets required to support piping, headers, and equipment, but not shown, shall be provided under this section. Material used for support shall be as specified under Section 05 12 00 STRUCTURAL STEEL. 3.1.11 Pipe Alignment Guides
Pipe alignment guides shall be provided where indicated for expansion loops, offsets, and bends and as recommended by the manufacturer for expansion joints, not to exceed 5 feet on each side of each expansion joint, and in lines 4 inches or smaller not more than 2 feet on each side of the joint. 3.1.12 Pipe Anchors
Anchors shall be provided where indicated. Unless indicated otherwise, anchors shall comply with the requirements specified. Anchors shall consist of heavy steel collars with lugs and bolts for clamping and attaching anchor braces, unless otherwise indicated. Anchor braces shall be installed in the most effective manner to secure the desired results using turnbuckles where required. Supports, anchors, or stays shall not be attached where they will injure the structure or adjacent construction during installation or by the weight SECTION 23 64 26 Page 30
123044
of expansion of the pipeline. Where pipe and conduit penetrations of vapor barrier sealed surfaces occur, these items shall be anchored immediately adjacent to each penetrated surface, to provide essentially zero movement within penetration seal. 3.1.13 Building Surface Penetrations
Sleeves shall not be installed in structural members except where indicated or approved. Except as indicated otherwise piping sleeves shall comply with requirements specified. Sleeves in nonload bearing surfaces shall be galvanized sheet metal, conforming to ASTM A653/A653M, Coating Class G-90, 20 gauge. Sleeves in load bearing surfaces shall be uncoated carbon steel pipe, conforming to ASTM A53/A53M, [Schedule 30][Schedule 20][Standard weight]. Sealants shall be applied to moisture and oil-free surfaces and elastomers to not less than 1/2 inch depth. Sleeves shall not be installed in structural members. 3.1.13.1 Refrigerated Space
Refrigerated space building surface penetrations shall be fitted with sleeves fabricated from hand-lay-up or helically wound, fibrous glass reinforced polyester or epoxy resin with a minimum thickness equal to equivalent size Schedule 40 steel pipe. Sleeves shall be constructed with integral collar or cold side shall be fitted with a bonded slip-on flange or extended collar. In the case of masonry penetrations where sleeve is not cast-in, voids shall be filled with latex mixed mortar cast to shape of sleeve and flange/external collar type sleeve shall be assembled with butyl elastomer vapor barrier sealant through penetration to cold side surface vapor barrier overlap and fastened to surface with masonry anchors. Integral cast-in collar type sleeve shall be flashed [as indicated.] [with not less than 4 inches of cold side vapor barrier overlap of sleeve surface.] Normally noninsulated penetrating round surfaces shall be sealed to sleeve bore with mechanically expandable seals in vapor tight manner and remaining warm and cold side sleeve depth shall be insulated with not less than [4][_____] inches of foamed-in-place rigid polyurethane or foamed-in-place silicone elastomer. Vapor barrier sealant shall be applied to finish warm side insulation surface. Warm side of penetrating surface shall be insulated beyond vapor barrier sealed sleeve insulation for a distance which prevents condensation. Wires in refrigerated space surface penetrating conduit shall be sealed with vapor barrier plugs or compound to prevent moisture migration through conduit and condensation therein. 3.1.13.1 General Service Areas
Each sleeve shall extend through its respective wall, floor, or roof, and shall be cut flush with each surface. Pipes passing through concrete or masonry wall or concrete floors or roofs shall be provided with pipe sleeves fitted into place at the time of construction. Sleeves shall be of such size as to provide a minimum of 1/4 inch all-around clearance between bare pipe and sleeves or between jacketed-insulation and sleeves. Except in pipe chases or interior walls, the annular space between pipe and sleeve or between jacket over-insulation and sleeve shall be sealed in accordance with Section 07 92 00 JOINT SEALANTS.
SECTION 23 64 26
Page 31
123044
3.1.13.2
Waterproof Penetrations
Pipes passing through roof or floor waterproofing membrane shall be installed through a .17 ounce copper sleeve, or a 0.032 inch thick aluminum sleeve, each within an integral skirt or flange. Flashing sleeve shall be suitably formed, and skirt or flange shall extend not less than 8 inches from the pipe and be set over the roof or floor membrane in a troweled coating of bituminous cement. The flashing sleeve shall extend up the pipe a minimum of 2 inches above the roof or floor penetration. The annular space between the flashing sleeve and the bare pipe or between the flashing sleeve and the metal-jacket-covered insulation shall be sealed as indicated. Penetrations shall be sealed by either one of the following methods. a. Waterproofing Clamping Flange: Pipes up to and including 10 inches in diameter passing through roof or floor waterproofing membrane may be installed through a cast iron sleeve with caulking recess, anchor lugs, flashing clamp device, and pressure ring with brass bolts. Waterproofing membrane shall be clamped into place and sealant shall be placed in the caulking recess. Modular Mechanical Type Sealing Assembly: In lieu of a waterproofing clamping flange, a modular mechanical type sealing assembly may be installed. Seals shall consist of interlocking synthetic rubber links shaped to continuously fill the annular space between the pipe/conduit and sleeve with corrosion protected carbon steel bolts, nuts, and pressure plates. Links shall be loosely assembled with bolts to form a continuous rubber belt around the pipe with a pressure plate under each bolt head and each nut. After the seal assembly is properly positioned in the sleeve, tightening of the bolt shall cause the rubber sealing elements to expand and provide a watertight seal rubber sealing elements to expand and provide a watertight seal between the pipe/conduit seal between the pipe/conduit and the sleeve. Each seal assembly shall be sized as recommended by the manufacturer to fit the pipe/conduit and sleeve involved. The Contractor electing to use the modular mechanical type seals shall provide sleeves of the proper diameters. 3.1.13.3 Fire-Rated Penetrations
b.
Penetration of fire-rated walls, partitions, and floors shall be sealed as specified in Section 07 84 00 FIRESTOPPING. 3.1.13.4 Escutcheons
Finished surfaces where exposed piping, bare or insulated, pass through floors, walls, or ceilings, except in boiler, utility, or equipment rooms, shall be provided with escutcheons. Where sleeves project slightly from floors, special deep-type escutcheons shall be used. Escutcheon shall be secured to pipe or pipe covering. 3.1.14 Access Panels
Access panels shall be provided where indicated for all concealed valves, vents, controls, and additionally for items requiring inspection or maintenance. Access panels shall be of sufficient size and located so that the concealed items may be serviced and maintained or completely removed SECTION 23 64 26 Page 32
123044
and replaced. Access panels shall be as specified in[ Section 05 50 13 MISCELLANEOUS METAL FABRICATIONS][ Section 05 51 33 METAL LADDERS][ Section 05 52 00 METAL RAILINGS][ Section 05 51 00 METAL STAIRS]. 3.2 ELECTRICAL INSTALLATION
Install electrical equipment in accordance with NFPA 70 and manufacturers instructions. 3.3 HEAT TRACE CABLE INSTALLATION
Heater tape shall be field applied and cut to fit as necessary, linearly along the length of pipe after piping has been pressure tested and approved by the Contracting Officer. Secure the heater to piping with cable ties or fiberglass tape. Thermal insulation shall be labeled on the outside, "Electrical Heat Trace." Power connection, end seals, splice kits and tee kit components shall be installed in accordance with IEEE 515 to provide a complete workable system. Connection to the thermostat and ends of the heat tape shall be terminated in a junction box. Cable and conduit connections shall be raintight. 3.4 HEAT TRACE CABLE TESTS
Test heat trace cable system in accordance with IEEE 515 after installation and before and after installation of the thermal insulation. Test heater cable using a 1000 vdc megger. Minimum insulation resistance shall be 20 to 1000 megohms regardless of cable length. 3.5 CLEANING AND ADJUSTING
Pipes shall be cleaned free of scale and thoroughly flushed of all foreign matter. A temporary bypass shall be provided for all water coils to prevent flushing water from passing through coils. Strainers and valves shall be thoroughly cleaned. Prior to testing and balancing, air shall be removed from all water systems by operating the air vents. Temporary measures, such as piping the overflow from vents to a collecting vessel shall be taken to avoid water damage during the venting process. Air vents shall be plugged or capped after the system has been vented. Control valves and other miscellaneous equipment requiring adjustment shall be adjusted to setting indicated or directed. 3.6 FIELD TESTS
Field tests shall be conducted in the presence of the QC Manager or his designated representative to verify systems compliance with specifications. Any material, equipment, instruments, and personnel required for the test shall be provided by the Contractor. 3.6.1 Equipment and Component Isolation
Prior to testing, equipment and components that cannot withstand the tests shall be properly isolated. 3.6.2 Pressure Tests
Each piping system shall be hydrostatically tested at a pressure not less than 188 psig for period of time sufficient to inspect every joint in the SECTION 23 64 26 Page 33
123044
system and in no case less than 2 hours. Test pressure shall be monitored by a currently calibrated test pressure gauge. Leaks shall be repaired and piping retested until test requirements are met. No leakage or reduction in gage pressure shall be allowed. Leaks shall be repaired by rewelding or replacing pipe or fittings. Caulking of joints will not be permitted. Concealed and insulated piping shall be tested in place before concealing. Submit for approval pressure tests reports covering the above specified piping pressure tests; describe the systems tested, test results, defects found and repaired, and signature of the pressure tests' director. Obtain approval from the QC Manager before concealing piping or applying insulation to tested and accepted piping. 3.4.3 Condenser Water Quality Test Reports
The condenser water system shall be analyzed by the water treatment company a minimum of once a month for a period of one year after system acceptance. Submit for approval the specified condenser water quality test reports. The analysis and resulting reports shall include the following information recorded in accordance with ASTM D 596. Date of Sample Temperature Silica (SiO2) Insoluble Iron and Aluminum Oxides Calcium (Ca) Magnesium (Mg) Sodium and Potassium (Na and K) Carbonate (HCO3) Sulfate (SO4) Chloride (Cl) Nitrate (NO3) Turbidity pH Residual Chlorine Total Alkalinity Non-Carbonate Hardness Total Hardness Dissolved Solids Fluorine Conductivity 3.6.3 3.6.3.1 Related Field Inspections and Testing Piping Welds [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____] [_____]
degrees F. ppm (mg/1) ppm (mg/1) ppm (mg/1) ppm (mg/1) ppm (mg/1) ppm (mg/1) ppm (mg/1) ppm (mg/1) ppm (mg/1) ppm (mg/1) unit ppm (mg/1) epm (meq/1) epm (meq/1) epm (meq/1) ppm (mg/1) ppm (mg/1) microhm/cm
Examination of Piping Welds is specified in the paragraph above entitled "Examination of Piping Welds". 3.6.3.2 HVAC TAB
Requirements for testing, adjusting, and balancing (TAB) of HVAC water piping, and associated equipment is specified in Section 23 05 93 TESTING,ADJUSTING, AND BALANCING FOR HVAC. Coordinate with the TAB team, and provide support personnel and equipment as specified in Section 23 05 93 TESTING, ADJUSTING AND BALANCING FOR HVAC to assist TAB team to meet the SECTION 23 64 26 Page 34
123044
TAB work requirements. 3.7 INSTRUCTION TO GOVERNMENT PERSONNEL
Furnish the services of competent instructors to give full instruction to the designated Government personnel in the adjustment, operation, and maintenance, including pertinent safety requirements, of the [chilled water, ] [chilled-hot water,][ and][ condenser heat reclaim water piping system[s]]. Instructors shall be thoroughly familiar with all parts of the installation and shall be instructed in operating theory as well as practical operation and maintenance work. Submit a lesson plan for the instruction course for approval. The lesson plan and instruction course shall be based on the approved operation and maintenance data and maintenance manuals. Conduct a training course for the operating staff and maintenance staff selected by the Contracting Officer. Give the instruction during the first regular work week after the equipment or system has been accepted and turned over to the Government for regular operation. The number of man-days (8 hours per day) of instruction furnished shall be [one man-day. ][[_____][_____] continuous man-days]. Use approximately half of the time for classroom instruction and the other time for instruction at the location of equipment or system. When significant changes or modifications in the equipment or system are made under the terms of the contract, provide additional instruction to acquaint the operating personnel with the changes or modifications. [3.6 ONE-YEAR INSPECTION REPORT FOR COOLING WATER
At the conclusion of the one year period, each connecting [cooling tower] [and] [liquid chiller condenser] inspect for problems due to corrosion, scale, and biological growth. If the equipment is found not to conform to the manufacturers recommended conditions, and the water treatment company recommendations have been followed; the water treatment company shall provide all chemicals and labor for cleaning or repairing the equipment as required by the manufacturer's recommendations.] -- End of Section --
SECTION 23 64 26
Page 35
123044
SECTION 23 81 00.00 20 UNITARY AIR CONDITIONING EQUIPMENT 11/09 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. AIR-CONDITIONING, HEATING AND REFRIGERATION INSTITUTE (AHRI) AHRI DCUP (Online) Directory of Certified Unitary Products
AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE) ANSI/ASHRAE 15 & 34 (2010; Addenda a, b, c, d, e, f, g, h, I, j, k, l, n and o; Errata 2011) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants (2010; INT 1 2011; Errata 2011, Errata 2011; Errata 2011, INT 2-12 2011, Errata 2011; INT 13 2012) Energy Standard for Buildings Except Low-Rise Residential Buildings
ASHRAE 90.1 - IP
AMERICAN WELDING SOCIETY (AWS) AWS A5.8/A5.8M (2011) Specification for Filler Metals for Brazing and Braze Welding
ASME INTERNATIONAL (ASME) ASME B16.22 (2001; R 2010) Standard for Wrought Copper and Copper Alloy Solder Joint Pressure Fittings (2010) Refrigeration Piping and Heat Transfer Components
ASME B31.5
ASTM INTERNATIONAL (ASTM) ASTM A123/A123M (2009) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products (2011) Standard Practice for Operating Salt Spray (Fog) Apparatus (2008) Standard Specification for Seamless SECTION 23 81 00.00 20 Page 1
ASTM B117
ASTM B280
123044
Copper Tube for Air Conditioning and Refrigeration Field Service ASTM B88 (2009) Standard Specification for Seamless Copper Water Tube (2011) Standard Specification for Preformed Flexible Elastomeric Cellular Thermal Insulation in Sheet and Tubular Form (2008) Evaluation of Painted or Coated Specimens Subjected to Corrosive Environments (1984; R 1990) Filter Units, Air Conditioning: Viscous-Impingement Type, Cleanable
ASTM C534/C534M
ASTM D1654
ASTM F872
MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS) MSS SP-58 (2009) Pipe Hangers and Supports Materials, Design and Manufacture, Selection, Application, and Installation (2003) Pipe Hangers and Supports Selection and Application (ANSI Approved American National Standard)
MSS SP-69
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA ICS 1 (2000; R 2005; R 2008) Standard for Industrial Control and Systems: General Requirements (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload Relays Rated 600 V (1993; R 2011) Enclosures (2011) Motors and Generators
NEMA ICS 2
U.S. ENVIRONMENTAL PROTECTION AGENCY (EPA) Energy Star (1992; R 2006) Energy Star Energy Efficiency Labeling System
U.S. GENERAL SERVICES ADMINISTRATION (GSA) CID A-A-50502 (Basic) Air Conditioners, (Unitary Heat Pump), Air to Air (3,000 to 300,000 BTU) (Rev D; Notice 1) Air Conditioners, Single Package Type (Rev C; Notice 1) Air Conditioners with Remote Condensing Units or Remote SECTION 23 81 00.00 20 Page 2
FS OO-A-373
FS OO-A-374
123044
Air-Cooled, and Water-Cooled Condenser Units, Unitary U.S. GREEN BUILDING COUNCIL (USGBC) LEED NC (2009) Leadership in Energy and Environmental Design(tm) New Construction Rating System UNDERWRITERS LABORATORIES (UL) UL 109 (1997; Reprint May 2009) Tube Fittings for Flammable and Combustible Fluids, Refrigeration Service, and Marine Use (2007; Reprint Jan 2010) Standard for Temperature-Indicating and -Regulating Equipment
UL 873
1.2
Section 23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS, applies to this section with the additions and modifications specified herein. 1.3 SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are [for Contractor Quality Control approval.][for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] The following shall be submitted in accordance with Section 01 33 00.05 20 CONSTRUCTION SUBMITTAL PROCEDURES: SD-02 Shop Drawings Field-assembled refrigerant piping Control system wiring diagrams SD-03 Product Data Room air conditioners Packaged terminal units Heat pumps, air to air Air conditioners Submit documentation for Energy Star qualifications or meeting FEMP requirements. Indicate Energy Efficiency Rating. Filters; (LEED NC) [ Submit documentation indicating type of biobased material in product and biobased content. Indicate relative dollar value of biobased content products to total dollar value of products included in project. Submit documentation indicating relative dollar value of rapidly renewable materials to total dollar value SECTION 23 81 00.00 20 Page 3
123044
of products included in project.] Thermostats Refrigerant piping and accessories Coatings for finned tube coils For packaged terminal units, include indoor noise rating. [ Local/Regional Materials Submit documentation indicating distance between manufacturing facility and the project site. Indicate distance of raw material origin from the project site. Indicate relative dollar value of local/regional materials to total dollar value of products included in project.] [ Environmental Data] SD-06 Test Reports Salt-spray tests Start-up and initial operational tests SD-08 Manufacturer's Instructions Room air conditioners Packaged terminal units Heat pumps, air to air Air conditioners Filters Thermostats Refrigerant piping and accessories SD-10 Operation and Maintenance Data Room air conditioners, Data Package 3 Packaged terminal units, Data Package 3 Heat pumps, air to air, Data Package 3 Air conditioners, Data Package 3 Filters, Data Package 2 Thermostats, Data Package 2 Submit in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA.
SECTION 23 81 00.00 20
Page 4
123044
SD-11 Closeout Submittals Posted operating instructions 1.4 1.4.1 QUALITY ASSURANCE Modification of References
Accomplish work in accordance with the referenced publications, except as modified by this section. Consider the advisory or recommended provisions to be mandatory, as though the word "shall" had been substituted for the words "should" or "could" or "may," wherever they appear. Interpret reference to "the Authority having jurisdiction," "the Administrative Authority," "the Owner," or "the Design Engineer" to mean the Contracting Officer. 1.4.2 Detail Drawing Submit
For refrigerant piping, submit piping, including pipe sizes. control system wiring diagrams. 1.4.3 Safety
Design, manufacture, and installation of unitary air conditioning equipment shall conform to ANSI/ASHRAE 15 & 34. 1.4.4 Posted Operating Instructions
Submit posted operating instructions for each packaged air conditioning unit. 1.4.5 Sizing
Size equipment based on Design Manual CS from the Air Conditioning Contractors of America; do not oversize. 1.5 REFRIGERANTS
Refrigerants shall have an Ozone Depletion Factor (ODF) of 0.05 or less. The ODF shall be in accordance with the "Montreal Protocol On Substances That Deplete The Ozone Layer," September 1987, sponsored by the United Nations Environment Programme. CFCs[ and HCFCs][ and Halons] shall not be permitted. Refrigerant shall be an approved alternative refrigerant per EPA's Significant New Alternative Policy (SNAP) listing. [Use HCFC-22 refrigerant.] 1.6 ENVIRONMENTAL REQUIREMENTS
For proper Indoor Environmental Quality, maintain positive pressure within the building. Ventilation shall meet or exceed ASHRAE 62.1 and all published addenda. Meet or exceed filter media efficiency as tested in accordance with ASHRAE 52.2. Thermal comfort shall meet or exceed ASHRAE 55. 1.7 1.7.1 SUSTAINABLE DESIGN REQUIREMENTS Local/Regional Materials
Use materials or products extracted, harvested, or recovered, as well as manufactured, within a [500][_____] mileradius from the project site, if SECTION 23 81 00.00 20 Page 5
123044
available from a minimum of three sources. 1.7.2 Environmental Data
[Submit Table 1 of ASTM E2129 for the following products: [_____].] PART 2 PRODUCTS
2.1
ROOM AIR CONDITIONERS
AHAM RAC-1 and UL 484. Minimum [seasonal ]energy efficiency ratio ([S]EER) shall be [in accordance with ASHRAE 90.1 IP, at a minimum.] [ [_____] [S]EER.] [Minimum integrated part load value (IPLV) shall be [in accordance with ASHRAE 90.1 IP, at a minimum.] [[_____] IPLV.]] Provide units removable from inside the building for servicing without removing the outside cabinet. Construct outside cabinets, including metal grilles to protect condenser coils, of zinc-coated steel or aluminum. Steel and zinc-coated surfaces shall receive at least one coat of primer and manufacturer's standard factory-applied finish Insulate cabinets to prevent condensation and run off of moisture. Provide mounting hardware made of corrosion-resistant material or protected by a corrosion-resistant finish. Provide air filters of the [throw-away] [or] [permanent washable] type removable without the use of tools and arranged to filter both room and ventilating air. Remove condensate by means of a drain or by evaporation and diffusion. Provide with metal or plastic mounting flanges on each side, top, and bottom of unit. For thru-the-wall installations provide aluminum or shop painted zinc-coated steel flanged telescopic wall sleeves. Design wall sleeves to restrict driving rain. For window mounted units provide shop-painted metal mounting brackets, braces, and sill plates. Mount compressors on vibration isolators. Minimum cooling capacity shall be not less than that indicated. Provide units listed in the AHAM RAC-1. [Provide light tight units serving dark rooms.] 2.1.1 Units for Operation on 115 Volts
Provide 3-wire cords of manufacturer's standard length. If not existing, provide a receptacle within reach of the standard length cord. Cords shall have a 15- or 20-amp, 3-pole, 125-volt ground type plug to match receptacle. 2.1.2 Units for Operation on 208 or 230 Volts
Provide 3-wire cords of manufacturer's standard length. If not existing, provide a receptacle within reach of the standard length cord. Cords shall have a 15-, 20-, or 30-amp, 3-pole, 250-volt ground type plug to match receptacle. 2.1.3 Controls
Mount controls in cabinet. Manual controls shall permit operation of either the fan or the fan and refrigerating equipment. Fan control shall provide two fan speed settings. Automatic controls shall include a thermostat for controlling air temperature. Thermostat shall have an adjustable range, including 72 to 80 degrees Fand shall automatically turn the refrigeration system on or off to maintain the preselected temperature within plus or minus 4 degrees F.
SECTION 23 81 00.00 20
Page 6
123044
2.2 2.2.1
PACKAGED TERMINAL UNITS Heat Pumps
ANSI/AHRI/CSA 310/380, UL 484, air-cooled, thru-wall type, ARI certified, and UL listed. [Minimum energy efficiency shall be in accordance with ASHRAE 90.1 - IP, at a minimum.] [Heat pumps shall have a minimum energy efficiency ratio (EER) of [_____], a minimum Coefficient of Performance (COP) of [_____], and a minimum integrated part load value (IPLV) of [_____].] Provide units listed in AHRI DCAACP. [Provide supplemental electric resistance heaters integral with unit.] [Provide units suitable for use with minimal ductwork having a total external static resistance up to 0.1 inch of water.] 2.2.2 Air Conditioners
ANSI/AHRI/CSA 310/380, UL 484, air-cooled, thru-wall type, ARI certified, and UL listed. Provide units with [heating only] [cooling only] [combination heating and cooling] section with indicated capacity. Minimum [seasonal ]energy efficiency ratio ([S]EER) shall be [in accordance with ASHRAE 90.1 - IP, at a minimum.] [[_____] [S]EER.] [Minimum integrated part load value (IPLV) shall be [in accordance with ASHRAE 90.1 - IP, at a minimum.] [[_____] IPLV.]] Provide units listed in AHRI DCAACP. [Provide units suitable for use with minimal ductwork having a total external static resistance up to 0.1 inch of water.] 2.2.3 Indoor Noise Rating
Rate in accordance with AHRI 350. Indoor rating shall not exceed [_____] bels while entire unit is operating at any fan or compressor speed. 2.2.4 Room Cabinets
Fabricate of 18-gage minimum steel (MSS). Provide removable front panel and access panels for equipment machinery, coils, controls, and filters. In lieu of steel, front panel may be constructed of high impact styrene structural foam conforming to requirements of UL 484. Structural foam shall pass tests specified in UL 484 for classification of 94 HB. Line interior of steel cabinets with insulation having a fire hazard rating not exceeding 25 for flame spread, and 50 for smoke developed, as determined by ASTM E84. Caulk around floor mounted units at the floor. Locate wall-mounted units 2 1/2 inches minimum above the floor. 2.2.5 Grilles
Provide manufacturer's [standard] [architectural] anodized aluminum outdoor grilles and caulk and seal on all sides when required by manufacturer's instructions. Provide both horizontal and vertical adjustable deflection inside air supply grilles. Provide for air return under the front panel or a return air grille in the lower part of the front panel. 2.2.6 Wall Sleeves and Mounts
Provide manufacturer's standard wall sleeves and mounts. Wall sleeves shall have seals designed to restrict driving rain and wind. [Provide unit subbase of the same construction and finish as the sleeve to provide for concealed electrical connection, cord storage, and equipped with unit leveling legs.] [Provide subbase with 24-volt remote control circuitry and wall mounted thermostat.] SECTION 23 81 00.00 20 Page 7
123044
2.2.7 [a.
Heating Section for Air Conditioners Electric Coils: Electric resistance heating elements with high temperature-limit safety device, factory-mounted, and wired to chassis.] Hot Water Coils: Serpentine type constructed of seamless copper tubes with aluminum fins mechanically or hydraulically bonded to tubes. Provide factory-furnished tee and manual air vent on return connection. Factory test coils at twice maximum operating pressure.] Steam Coils: Serpentine type constructed of red brass or seamless copper tubes with aluminum fins mechanically or hydraulically bonded to tubes. Factory test coils at twice the maximum operating pressure.] Heating unit shall have internal thermal insulation having a fire hazard rating not to exceed 25 for flame spread and 50 for smoke developed as determined by ASTM E84. Refrigeration Sections
[b.
[c.
d.
2.2.8
Completely self-contained, slide-in assembly or removable chassis with welded, hermetically sealed, air-cooled refrigeration system, outdoor fan, indoor fan, control box, and ventilation damper. Provide refrigeration sections capable of installation or removal without the use of tools. Refrigeration sections shall include refrigeration circuit tubing, wiring, and safety controls, and shall operate down to 35 degrees F outdoor temperature and 70 degrees F indoor temperature, without compressor short cycling while delivering not less than 100 percent of rated cooling capacity. Units shall have drains to the building exterior to eliminate excess driving rain. Condensate shall not drain onto building exterior or interior. a. b. Compressors: Hermetic type with vibration isolation devices.
Coils: Constructed of seamless copper or aluminum tubing with copper or aluminum fins bonded to tubes. [Coat outdoor air coils with factory applied corrosion resistant treatment. Coils to be coated shall be part of manufacturer's standard product for capacities and ratings indicated and specified. Provide plate type fins.] Outdoor Fans: Direct connected centrifugal type with aluminum or plastic wheel and forward curved blades or direct connected aluminum propeller type. Design fans so that condensate will evaporate without drip, splash, or spray on building exterior. Indoor Fans: Direct connected centrifugal type with aluminum, galvanized steel, or plastic wheel and forward curved blades. Provide minimum two-speed motor with built-in overload protection. Ventilation Damper Assembly
c.
d.
2.2.9
Operated by automatic actuator. Dampers shall close on unit shutdown or loss of power and shall open on heating or cooling start-up. 2.2.10 Air Filters
Removable without use of tools, and shall filter both recirculated and ventilating air. SECTION 23 81 00.00 20 Page 8
123044
2.2.11
Controls
Provide controls including, an adjustable thermostat, and switches, to regulate room air temperature through control of refrigerant compressors or heating elements. Controls shall at least have positions for off, high or low fan speed for [heating] [and] [cooling], and fan only operation. [Provide remote mounted night set-back thermostat.] 2.1 HEAT PUMPS, AIR TO AIR
CID A-A-50502, except as modified in this article; Type II[_____], Class 1 [_____]. List units with capacities smaller than 135,000 Btu/hr in the [ AHRI DCUP]; in lieu of listing in the ARI Directory, a letter of certification from ARI that the units have been certified and will be listed in the next Directory will be acceptable. Provide factory assembled units complete with accessories, wiring, piping, and controls. Provide units with [outlet grilles,.] [supplemental electric heaters.] [humidifiers.] [and air filters as specified in the paragraph entitled "Filters."] 2.1.1 Energy Performance
[Energy performance shall be in accordance with CID A-A-50502. ][Minimum energy efficiency shall be in accordance with ASHRAE 90.1 - IP.] [Heat pumps shall have [a minimum [seasonal] energy efficiency ratio ([S]EER) of [_____]14.0,] [a minimum Heating Seasonal Performance Factor (HSPF) of [_____]9.3,] [a minimum Integrated Part Load Value (IPLV) of [_____],] and [ a minimum COP of [_____]3.0.]] 2.1.2 Air Coils
Extended-surface fin and tube type with seamless copper or aluminum tubes with copper or aluminum fins securely bonded to the tubes. On coils with all-aluminum construction, provide tubes of aluminum alloy 1100, 1200, or 3102; provide fins of aluminum alloy 7072; and provide tube sheets of aluminum alloy 7072 or 5052. [Provide a coating on [outdoor air] [and] [indoor air] coils as specified in the paragraph entitled "Coatings for Finned Tube Coils." Coils to be coated shall be part of manufacturer's standard product for capacities and ratings indicated and specified. Provide plate type fins.] 2.3.3 Supplemental Electric Heaters
Provide electrical resistance heaters [integral with the unit] [for remote installation in ductwork]. Heaters shall have a total capacity as indicated. Provide internal fusing for heaters. 2.1.3 Compressors
For compressors above 20 tons, compressor speed shall not exceed 3450 rpm. For equipment over 10 tons, provide automatic capacity reduction of at least 50 percent of rated capacity. Capacity reduction may be accomplished by cylinder unloading, use of multiple, but not more than four compressors, or a combination of the two methods. Units with cylinder unloading shall start with capacity reduction devices in the unloaded position. Units with multiple compressors shall have a means to sequence starting of compressors. Provide compressors with devices to prevent short cycling when shutdown by safety controls. Provide reciprocating compressors with SECTION 23 81 00.00 20 Page 9
123044
crankcase heaters, and vibration isolators. 2.1.4 Mounting Provisions
Provide units that permit mounting as indicated. [Provide suitable lifting attachment plates to enable equipment to be lifted to normal position.] 2.1.5 Temperature Controls
Provide controls as specified in CID A-A-50502 and as modified herein. Provide indoor thermostats of the adjustable type that conform to applicable requirements of UL 873. Provide manual means for temperature set-back. Provide thermostats capable of controlling supplemental heat as specified in CID A-A-50502. Provide a manual selector switch or other means to permit the supplementary heater to be energized when the heat pump compressor and associated equipment are inoperative. Control supplementary heater with the room thermostat while bypassing the outdoor thermostat. Locate switch adjacent to or as an integral part of the room thermostat. An indicator light on the room thermostat or manual heat switch shall indicate when supplementary heaters are operating. 2.1.6 Accessories
In addition to accessories specified in CID A-A-50502, provide the following accessories for heat pump units. a. [b. 2.4 2.4.1 Protective grille around outside unit coils Start capacitor kit] AIR CONDITIONERS Single Package Type
FS OO-A-373, except as modified herein; Type [_____], Style [_____], Class [_____]. Additional requirements for various system components are specified in this article; however, the basic requirements for the system and system components are contained in FS OO-A-373. Provide factory packaged [cooling] [combination heating and cooling] units. Provide units suitable for [indoor] [outdoor] [roof top] installation. [Provide units with suitable lifting attachments, [remote control panel] [roof curb and flashing], [and] [transition plenums].] [Minimum energy efficiency shall be in accordance with ASHRAE 90.1 - IP, at a minimum.] [Units shall have a minimum [SEER of [_____]] [EER of [_____]] [IPLV of [_____]] when tested in accordance with ANSI/AHRI 210/240 or ANSI/AHRI 340/360 as applicable.] List units with capacities smaller than 135,000 Btu/hr in the AHRI DCUP; in lieu of listing in the ARI Directory, a letter of certification from ARI that the units have been certified and will be listed in the next Directory will be acceptable. Provide capacity, electrical characteristics, and operating conditions as indicated. [Condensers shall provide not less than 10 degrees F liquid subcooling at standard ratings.] 2.4.2 Split-System Type
FS OO-A-374, except as modified herein; Type [_____], Style [_____], Class [_____]. Additional requirements for various system components are specified in this paragraph; however, basic requirements for the system and system components are contained in FS OO-A-374. Provide separate assemblies designed to be used together. Base ratings on the use of SECTION 23 81 00.00 20 Page 10
123044
matched assemblies. Provide performance diagrams for units with capacities not certified by ARI to verify that components of the air conditioning system furnished will satisfy the capacity requirement specified or indicated. [Minimum energy efficiency shall be in accordance with ASHRAE 90.1 - IP, at a minimum.] [Units shall have a minimum [SEER] [EER] of [_____] when tested in accordance with ANSI/AHRI 210/240 or ANSI/AHRI 340/360 as applicable.] List units with capacities smaller than 135,000 Btu/hr in the AHRI DCUP; in lieu of listing in the ARI Directory, a letter of certification from ARI that units have been certified and will be listed in the next Directory will be acceptable. Provide capacity, electrical characteristics and operating conditions as indicated. [Condensers shall provide not less than 10 degrees F liquid subcooling at standard ratings.] 2.4.3 Single Zone Units
Provide single zone type units arranged to [draw] [or] [blow] through coil sections. [Air may be blown or drawn through heating section.] 2.4.4 Multizone Units
Provide multizone type units arranged to [blow through the cooling and heating sections] [draw through the cooling and heating sections] [blow through the individual cooling and heating coils of each zone]. 2.4.5 Heaters
Provide as [an integral part of the evaporator-blower unit] [a separate unit for installation in the duct work]. Provide [steam coils] [hot water coils] [gas heaters] [oil heaters] [electric open coils] [electric strip tubular heaters] [electric fin tubular heaters]. 2.4.6 Compressors
For compressors over 20 tons, compressor speed shall not exceed 3450 rpm. For systems over 10 tons provide automatic capacity reduction of at least 50 percent of rated capacity. Capacity reduction may be accomplished by cylinder unloading, use of multi- or variable speed compressors, use of multiple, but not more than four compressors, or a combination of the two methods. Units with cylinder unloading shall start with capacity reduction devices in the unloaded position. Units with multiple compressors shall have means to sequence starting of compressors. Provide compressors with devices to prevent short cycling when shut down by safety controls. Device shall delay operation of compressor motor for at least 3 minutes but not more than 6 minutes. Provide a pumpdown cycle for units 20 tons and over. Provide reciprocating compressors with crankcase heaters in accordance with the manufacturer's recommendations. If compressors are paralleled, provide not less than two independent circuits. 2.4.7 Coils
On coils with all-aluminum construction, provide tubes of aluminum alloy 1100, 1200, or 3102; provide fins of aluminum alloy 7072; and provide tube sheets of aluminum alloy 7072 or 5052. Provide a separate air cooled condenser circuit for each compressor or parallel compressor installation. [Provide a coating on [condenser] [and] [evaporator] coils and fins as specified in the paragraph entitled "Coatings for Finned Tube Coils." Coils to be coated shall be part of manufacturer's standard product for capacities and ratings indicated and specified. Provide plate type fins.] SECTION 23 81 00.00 20 Page 11
123044
2.4.8
Condenser Controls
Provide start-up and head pressure controls to allow for system operation at ambient temperatures down to [_____] degrees F. 2.4.9 Fans
Provide belt-driven evaporator fans with adjustable pitch pulleys; except for units less than 5 ton capacity, direct drive with at least two speed taps may be used. Select pulleys at approximately midpoint of the adjustable range. 2.4.10 Filters
Provide filters of the type specified in this section. 2.4.11 Filter Boxes
Provide when filters are not included integral with air conditioning units. Construct of not less than No. 20 US gage steel with track, hinged access doors with latches, and gaskets between frame and filters. Arrange filters to filter outside and return air. Provide removable filter assemblies, replaceable without the use of tools. 2.4.12 Mixing Boxes
Provide of the physical size to match the basic unit and include equal sized flanged openings, sized to individually handle full air flow. Arrange openings as indicated. Provide openings with dampers of parallel or opposed blade type. Provide opposed blade type for modulating dampers and parallel type for two-position dampers. Connect damper shafts together by one continuous linkage bar. Arrange dampers for [automatic] [or] [manual] operation so that when one starts to close from its opened position, the other starts to open from its closed position. 2.4.13 Thermostats
Provide adjustable type that conforms to applicable requirements of UL 873. Provide combination heating-cooling type with contacts hermetically sealed against moisture, corrosion, lint, dust, and foreign material. Design to operate on not more than 1.5 degrees Fdifferential and of suitable range calibrated in degrees F. Provide adjustable heat anticipation and fixed cooling anticipation. Provide two independent temperature sensing elements electrically connected to control the compressor and heating equipment, respectively. Accomplish manual switching for system changeover from heating to cooling or cooling to heating and fan operation through the use of a thermostat subbase. Provide system selector switches to provide "COOL" and "OFF" and "HEAT" and fan selector switches to provide "AUTOMATIC" and "ON." Provide relays, contactors, and transformers located in a panel or panels for replacement and service. 2.4.13.1 a. Cooling
When thermostat is in "COOL" position with fan selector switch in "AUTO" position, compressor, evaporator fan, and condenser fan shall cycle together. When thermostat is in "COOL" position with fan selector switch in "ON" SECTION 23 81 00.00 20 Page 12
b.
123044
position, compressor, and condenser fan shall cycle together and evaporator fan shall run continuously. 2.4.13.2 a. Heating
When thermostat is in "HEAT" position with fan selector switch in "AUTO" position, heater and supply air fan shall cycle together. Provide a separate thermostat to keep the fan running until the heater cools. When thermostat is in "HEAT" position with fan selector switch in "ON" position, heater shall cycle and supply air fan shall run continuously. Supply Air Fan
b.
2.4.13.3 a.
When fan selector switch is in "AUTO" position with thermostat in "OFF" position, fan shall not run. When fan selector switch is in "ON" position, fan shall run continuously. FILTERS
b.
2.2
Provide filters to filter outside air and return air and locate [as indicated] [inside air conditioners] [inside filter box] [inside combination air filter mixing box]. Provide [replaceable (throw-away)] [high efficiency] [cleanable (reusable)] type. Filters shall conform to UL 900, [Class 1] [or] [Class 2]. Polyurethane filters shall not be used on units with multiframe filters.[ Filters shall contain a minimum of [85][95][_____] percent biobased material like cotton.] 2.5.1 Replaceable Type Filters
ASTM F1040 throw-away frames and media, standard dust holding capacity, 350 fpm maximum face velocity, and [ one inch] [ 2 inches] thick. Filters shall have a minimum efficiency reporting value (MERV) of [6][8][_____] when tested in accordance with ASHRAE 52.2. 2.5.2 High Efficiency Filters
Filters shall have a MERV of 17 when tested in accordance with ASHRAE 52.2. Filter assembly shall include; holding frame and fastener assembly, filter cartridge, mounting frame, and retainer assembly. Reinforce filter media with glass fiber mat. Pressure drop across clean filter shall not exceed [_____] inches of watergage. Precede high efficiency filters with a UL Class 2 replaceable type filter. 2.2.1 Cleanable Type Filters
ASTM F872, Type II, UL Class 2. Provide sufficient oil to coat filters six times based on one pint of oil per each 10 square feet of filter area. Provide washing and charging tanks for cleaning and coating filters. Filters shall have a MERV of [6][8][_____] when tested in accordance with ASHRAE 52.2. 2.5.4 Manometers
Provide inclined-type manometers for filter stations of 2,000 cfm capacity or larger including filters furnished as integral parts of air-handling SECTION 23 81 00.00 20 Page 13
123044
units and filters installed separately. Provide sufficient length to read at least one inch of water column with 10 major graduations, and equipped with spirit level. Equip manometers with overpressure safety traps to prevent loss of fluid, and two three-way vent valves for checking zero setting. [Mercury shall not be used as the operating fluid.] 2.3 COATINGS FOR FINNED TUBE COILS
Where stipulated in equipment specifications of this section, coat finned tube coils of the affected equipment as specified belowAll outdoor condensing units shall have fin coatings that meet the requirements of a 3000 hour salt spray exposure test. Apply coating at the premises of a company specializing in such work. Degrease and prepare for coating in accordance with the coating applicator's procedures for the type of metals involved. Completed coating shall show no evidence of softening, blistering, cracking, crazing, flaking, loss of adhesion, or "bridging" between the fins. 2.6.1 Phenolic Coating
Provide a resin base thermosetting phenolic coating. Apply coating by immersion dipping of the entire coil. Provide a minimum of two coats. Bake or heat dry coils following immersions. After final immersion and prior to final baking, spray entire coil with particular emphasis given to building up coating on sheared edges. Total dry film thickness shall be 2.5 to 3.0 mils. 2.6.2 Chemical Conversion Coating with Polyelastomer Finish Coat
Dip coils in a chemical conversion solution to molecularly deposit a corrosion resistant coating by electrolysis action. Chemical conversion coatings shall conform to MIL-DTL-5541, Class 1A. Cure conversion coating at a temperature of 110 to 140 degrees F for a minimum of 3 hours. Coat coil surfaces with a complex polymer primer with a dry film thickness of 1 mil. Cure primer coat for a minimum of 1 hour. Using dip tank method, provide three coats of a complex polyelastomer finish coat. After each of the first two finish coats, cure the coils for 1 hour. Following the third coat, spray a fog coat of an inert sealer on the coil surfaces. Total dry film thickness shall be 2.5 to 3.0 mils. Cure finish coat for a minimum of 3 hours. Coating materials shall have 300 percent flexibility, operate in temperatures of minus 50 to plus 220 degrees F, and protect against atmospheres of a pH range of 1 to 14. 2.6.3 Vinyl Coating
Apply coating using an airless fog nozzle. For each coat, make at least two passes with the nozzle. Materials to be applied are as follows: Total dry film thickness, 6.5 mils maximum. Vinyl Primer, 24 percent solids by volume: One coat 2 mils thick One coat 4.5 mils thick.
Vinyl Copolymer, 30 percent solids by volume: 2.4 MOTORS AND STARTERS
NEMA MG 1, NEMA ICS 1, and NEMA ICS 2. Variable speed. Motors less than 1 hp shall meet NEMA High Efficiency requirements. Motors 1 hp and larger shall meet NEMA Premium Efficiency requirements. Determine specific motor SECTION 23 81 00.00 20 Page 14
123044
characteristics to ensure provision of correctly sized starters and overload heaters. Provide motors to operate at full capacity with a voltage variation of plus or minus 10 percent of the motor voltage rating. Motor size shall be sufficient for the duty to be performed and shall not exceed its full load nameplate current rating when driven equipment is operated at specified capacity under the most severe conditions likely to be encountered. When motor size provided differs from size indicated or specified, the Contractor shall make the necessary adjustments to the wiring, disconnect devices, and branch circuit protection to accommodate equipment actually provided. [Provide reduced voltage type motor starters.] Provide [general-purpose] [weather-resistant] [watertight] [explosion proof]appropriate for the installation location type starter enclosures in accordance with NEMA ICS 6. 2.5 REFRIGERANT PIPING AND ACCESSORIES
Provide accessories as specified in [FS OO-A-373] [FS OO-A-374] [ CID A-A-50502] and this section. Provide suction line accumulators as recommended by equipment manufacturer's installation instructions. [Provide a filter-drier in the liquid line.] 2.5.1 Factory Charged Tubing
Provide extra soft, deoxidized, bright annealed copper tubing conforming to ASTM B280, factory dehydrated and furnished with a balanced charge of refrigerant recommended by manufacturer of equipment being connected. Factory insulate suction line tubing with 3/8 inch minimum thickness of closed cell, foamed plastic conforming to ASTM C534/C534M with a permeance rating not to exceed 1.0. Provide quick-connectors with caps or plugs to protect couplings. Include couplings for suction and liquid line connections of the indoor and outdoor sections. 2.5.2 Field-Assembled Refrigerant Piping
Material and dimensional requirements for field-assembled refrigerant piping, valves, fittings, and accessories shall conform to ANSI/ASHRAE 15 & 34 and ASME B31.5, except as herein specified. Factory clean, dehydrate, and seal piping before delivery to the project location. Provide seamless copper tubing, hard drawn, Type K or L, conforming to ASTM B88, except that tubing with outside diameters of 1/4 inch and 3/8 inch shall have nominal wall thickness of not less than 0.030 inch and 0.032 inch, respectively. Soft annealed copper tubing conforming to ASTM B280 may be used where flare connections to equipment are required only in nominal sizes less than one inch outside diameter. 2.5.3 Fittings UL 109 for flared tube fittings.
ASME B16.22 for solder-joint fittings. 2.5.4 Brazing Filler Material
AWS A5.8/A5.8M. 2.5.5 Pipe Hangers and Supports
MSS SP-69 and MSS SP-58, Type [_____]1, except as indicated otherwise.
SECTION 23 81 00.00 20
Page 15
123044
2.5.6
Pipe Sleeves
Provide sleeves where piping passes through walls, floors, roofs, and partitions. Secure sleeves in proper position and location during construction. Provide sleeves of sufficient length to pass through entire thickness of walls, floors, roofs, and partitions. Provide not less than 0.25 inch space between exterior of piping or pipe insulation and interior of sleeve. Firmly pack space with insulation and caulk at both ends of the sleeve with plastic waterproof cement which will dry to a firm but pliable mass, or provide a segmented elastomeric seal. 2.5.6.1 Sleeves in Masonry and Concrete Walls, Floors, and Roofs
Provide Schedule 40 or Standard Weight zinc-coated steel pipe sleeves. Extend sleeves in floor slabs 3 inches above finished floor. 2.5.6.2 Sleeves in Partitions and Non-Masonry Structures
Provide zinc-coated steel sheet sleeves having a nominal weight of not less than 0.90 pound per square foot, in partitions and other than masonry and concrete walls, floors, and roofs. 2.6 FINISHES
Provide steel surfaces of equipment including packaged terminal units, heat pumps, and air conditioners, that do not have a zinc coating conforming to \&[ASTM A123/A123M] [ASTM A653/A653M]&\, or a duplex coating of zinc and paint, with a factory applied coating or paint system. Provide a coating or paint system on actual equipment identical to that on salt-spray test specimens with respect to materials, conditions of application, and dry-film thickness. 2.7 2.7.1 SOURCE QUALITY CONTROL Salt-Spray Tests
Salt-spray test the factory-applied coating or paint system of equipment including packaged terminal units, heat pumps, and air conditioners in accordance with ASTM B117. Conduct test for 53000 hours for equipment installed outdoors, or 125 hours for equipment installed indoors exposed to outdoor air, or 125 hours for equipment installed indoors not exposed to outdoor air. Test specimens shall have a standard scribe mark as defined in ASTM D1654. Upon completion of exposure, evaluate and rate the coating or paint system in accordance with procedures A and B of ASTM D1654. Rating of failure at the scribe mark shall not be less than six, average creepage not greater than 1/8 inch. Rating of the unscribed area shall not be less than 10, no failure. PART 3 3.1 EXECUTION EQUIPMENT INSTALLATION
Install equipment and components in a manner to ensure proper and sequential operation of equipment and equipment controls. Install equipment not covered in this section, or in manufacturer's instructions, as recommended by manufacturer's representative. Provide proper foundations for mounting of equipment, accessories, appurtenances, piping and controls including, but not limited to, supports, vibration isolators, stands, guides, anchors, clamps and brackets. Foundations for equipment SECTION 23 81 00.00 20 Page 16
123044
shall conform to equipment manufacturer's recommendation, unless otherwise indicated. Set anchor bolts and sleeves using templates. Provide anchor bolts of adequate length, and provide with welded-on plates on the head end embedded in the concrete. Level equipment bases, using jacks or steel wedges, and neatly grout-in with a nonshrinking type of grouting mortar. Locate equipment to allow working space for servicing including shaft removal, disassembling compressor cylinders and pistons, replacing or adjusting drives, motors, or shaft seals, access to water heads and valves of shell and tube equipment, tube cleaning or replacement, access to automatic controls, refrigerant charging, lubrication, oil draining and working clearance under overhead lines. Provide electric isolation between dissimilar metals for the purpose of minimizing galvanic corrosion. 3.1.1 Packaged Terminal Air Conditioners and Heat Pumps
Wall sleeve installation shall provide a positive weathertight and airtight seal. 3.1.2 Unitary Air Conditioning System
Install as indicated, in accordance with requirements of ANSI/ASHRAE 15 & 34, and the manufacturer's installation and operational instructions. 3.1.3 Room Air Conditioners
Install units in accordance with manufacturer's instructions. Provide structural mountings, closures, and seals for weathertight assembly. Pitch unit as recommended by manufacturer to ensure condensate drain to drain pan without overflow. 3.2 PIPING
Brazing, bending, forming and assembly of refrigerant piping shall conform to ASME B31.5. 3.2.1 Pipe Hangers and Supports
Design and fabrication of pipe hangers, supports, and welding attachments shall conform to MSS SP-58. Installation of hanger types and supports for bare and covered pipes shall conform to MSS SP-69 for the system temperature range. Unless otherwise indicated, horizontal and vertical piping attachments shall conform to MSS SP-58. 3.2.2 Refrigerant Piping
Cut pipe to measurements established at the site and work into place without springing or forcing. Install piping with sufficient flexibility to provide for expansion and contraction due to temperature fluctuation. Where pipe passes through building structure pipe joints shall not be concealed, but shall be located where they may be readily inspected. Install piping to be insulated with sufficient clearance to permit application of insulation. Install piping as indicated and detailed, to avoid interference with other piping, conduit, or equipment. Except where specifically indicated otherwise, run piping plumb and straight and parallel to walls and ceilings. Trapping of lines will not be permitted except where indicated. Provide sleeves of suitable size for lines passing through building structure. Braze refrigerant piping with silver solder complying with AWS A5.8/A5.8M. Inside of tubing and fittings shall be free of flux. Clean parts to be jointed with emery cloth and keep hot until SECTION 23 81 00.00 20 Page 17
123044
solder has penetrated full depth of fitting and extra flux has been expelled. Cool joints in air and remove flame marks and traces of flux. During brazing operation, prevent oxide film from forming on inside of tubing by slowly flowing dry nitrogen through tubing to expel air. Make provisions to automatically return oil on halocarbon systems. Installation of piping shall comply with ASME B31.5. 3.2.3 Returning Oil From Refrigerant System
Install refrigerant lines so that gas velocity in the evaporator suction line is sufficient to move oil along with gas to the compressor. Where equipment location requires vertical risers, line shall be sized to maintain sufficient velocity to lift oil at minimum system loading and corresponding reduction of gas volume. Install a double riser when excess velocity and pressure drop would result from full system loading. Larger riser shall have a trap, of minimum volume, obtained by use of 90- and 45-degree ells. Arrange small riser with inlet close to bottom of horizontal line, and connect to top of upper horizontal line. Do not install valves in risers. 3.2.4 Refrigerant Driers, Sight Glass Indicators, and Strainers
Provide refrigerant driers, sight glass liquid indicators, and strainers in refrigerant piping in accordance with [FS OO-A-373] [FS OO-A-374] [ CID A-A-50502] when not furnished by the manufacturer as part of the equipment. Install driers in liquid line with service valves and valved bypass line the same size as liquid line in which dryer is installed. Size of driers shall be determined by piping and installation of the unit on location. Install dryers of 50 cubic inches and larger vertically with the cover for removing cartridge at the bottom. Install moisture indicators in the liquid line downstream of the drier. Indicator connections shall be the same size as the liquid line in which it is installed. 3.2.5 Strainer Locations and Installation
Locate strainers close to equipment they are to protect. Provide a strainer in common refrigerant liquid supply to two or more thermal valves in parallel when each thermal valve has a built-in strainer. Install strainers with screen down and in direction of flow as indicated on strainer's body. 3.2.6 Solenoid Valve Installation
Install solenoid valves in horizontal lines with stem vertical and with flow in direction indicated on valve. If not incorporated as integral part of the valve, provide a strainer upstream of the solenoid valve. Provide service valves upstream of the solenoid valve, upstream of the strainer, and downstream of the solenoid valve. Remove the internal parts of the solenoid valve when brazing the valve. 3.3 AUXILIARY DRAIN PANS, DRAIN CONNECTIONS, AND DRAIN LINES
Provide auxiliary drain pans under units located above finished ceilings or over mechanical or electrical equipment where condensate overflow will cause damage to ceilings, piping, and equipment below. Provide separate drain lines for the unit drain and auxiliary drain pans. Trap drain pans from the bottom to ensure complete pan drainage. Provide drain lines full size of drain opening. Traps and piping to drainage disposal points shall conform to Section 22 00 00 PLUMBING, GENERAL PURPOSE. SECTION 23 81 00.00 20 Page 18
123044
3.4
ACCESS PANELS
Provide access panels for concealed valves, controls, dampers, and other fittings requiring inspection and maintenance. 3.5 AIR FILTERS Install filters with suitable
Allow access space for servicing filters. sealing to prevent bypassing of air. 3.6 FLASHING AND PITCH POCKETS
Provide flashing and pitch pockets for equipment supports and roof penetrations and flashing where piping or ductwork passes through exterior walls in accordance with Section 07 60 00 FLASHING AND SHEET METAL. 3.7 IDENTIFICATION TAGS AND PLATES
Provide equipment, gages, thermometers, valves, and controllers with tags numbered and stamped for their use. Provide plates and tags of brass or suitable nonferrous material, securely mounted or attached. Provide minimum letter and numeral size of 1/8 inch high. 3.8 3.8.1 FIELD QUALITY CONTROL Leak Testing
Upon completion of installation of air conditioning equipment, test factory- and field-installed refrigerant piping with an electronic-type leak detector. Use same type of refrigerant to be provided in the system for leak testing. When nitrogen is used to boost system pressure for testing, ensure that it is eliminated from the system before charging. Minimum refrigerant leak field test pressure shall be as specified in ANSI/ASHRAE 15 & 34, except that test pressure shall not exceed 150 psig on hermetic compressors unless otherwise specified as a low side test pressure on the equipment nameplate. If leaks are detected at time of installation or during warranty period, remove the entire refrigerant charge from the system, correct leaks, and retest system. 3.8.2 Evacuation, Dehydration, and Charging
After field charged refrigerant system is found to be without leaks or after leaks have been repaired on field-charged and factory-charged systems, evacuate the system using a reliable gage and a vacuum pump capable of pulling a vacuum of at least one mm Hg absolute. Evacuate system in accordance with the triple-evacuation and blotter method or in accordance with equipment manufacturer's printed instructions and recharge system. 3.8.3 Start-Up and Initial Operational Tests
Test the air conditioning systems and systems components for proper operation. Adjust safety and automatic control instruments as necessary to ensure proper operation and sequence. Conduct operational tests for not less than 8 hours.
SECTION 23 81 00.00 20
Page 19
123044
3.8.4
Performance Tests
Upon completion of evacuation, charging, startup, final leak testing, and proper adjustment of controls, test the systems to demonstrate compliance with performance and capacity requirements. Test systems for not less than 8 hours, record readings hourly. At the end of the test period, average the readings, and the average shall be considered to be the system performance. Record the following readings: [_____]Outdoor Temperature [_____]Indoor Temperature 3.9 WASTE MANAGEMENT
Separate waste in accordance with the Waste Management Plan, placing copper materials in designated areas for reuse. Close and seal tightly all partly used adhesives and solvents; store protected in a well-ventilated, fire-safe area at moderate temperature. -- End of Section --
SECTION 23 81 00.00 20
Page 20
123044
SECTION 23 82 00.00 20 TERMINAL HEATING AND COOLING UNITS 11/08 PART 1 1.1 GENERAL REFERENCES
The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only. ASTM INTERNATIONAL (ASTM) ASTM A123/A123M (2009) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products (2009) Standing Practice for Operating Salt Spray (Fog) Apparatus (2008) Evaluation of Painted or Coated Specimens Subjected to Corrosive Environments
ASTM B117
ASTM D 1654
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload Relays Rated 600 V (1993; R 2006) Enclosures (2009) Motors and Generators
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA 211 (2010) Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances (2009; TIA 10-3) National Fuel Gas Code (2011; TIA 11-1; Errata 2011) National Electrical Code (2009; Errata 09-1) Standard for the Installation of Air Conditioning and Ventilating Systems (2009) Standard for the Installation of Warm Air Heating and Air Conditioning Systems (2010) Standard for Exhaust Systems for Air Conveying of Vapors, Gases, Mists and Noncombustible Particulate Solids
NFPA 54 NFPA 70
NFPA 90A
NFPA 90B
NFPA 91
SECTION 23 82 00.00 20
Page 1
123044
1.2
Section 23 03 00.00 20 BASIC MECHANICAL MATERIALS AND METHODS, applies to this section with additions and modifications specified herein. 1.3 SUBMITTALS
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are [for Contractor Quality Control approval.][for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.] The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES: SD-03 Product Data Unit heaters Infrared heaters SD-10 Operation and Maintenance Data Unit heaters, Data Package 2 Infrared heaters, Data Package 2 Submit in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA. PART 2 2.1 PRODUCTS UNIT HEATERS
Self-contained and factory assembled, [propeller] [or] [centrifugal] fan with capacities expressed as Btu per hour output and cubic foot-per-minute air delivery, operating conditions, and mounting arrangements as indicated. Average fan bearing life shall be minimum 200,000 hours at operating conditions. Provide fan motor with [direct] [or] [belt] drive. Construct fan-guard motor mount of steel wire. Equip each heater with individually adjustable package discharge louver. Louvers may be substituted by discharge cones or diffusers. Provide thermostats [as indicated]. Furnish circuit breaker disconnect switch. 2.1.1 Gas-Fired Unit Heater
ANSI Z83.8/CSA 2.6 and AGA label. 2.1.1.1 Casing Provide removable
Minimum [22] [_____] gage [steel] [or] [aluminum]. access panels. 2.1.1.2 Heat Exchanger
Minimum [20] [_____] gage all-welded steel construction with corrosion-resistant aluminum finish.
SECTION 23 82 00.00 20
Page 2
123044
2.1.1.3
Burners
Die-formed, slot ports, and steel construction with aluminum paint. 2.1.1.4 Draft Diverter
All-welded steel construction and an integral part of each heat exchanger section. Allows backdrafts to bypass burner assembly without affecting normal operation. 2.1.1.5 Controls
Consisting of a combination pressure regulator, [two-stage gas valve in 100 percent and [55] [_____] percent of full rating,] main shutoff valve, pilot cock, pilot safety switch for 100 percent shutoff, high temperature limit switch, and time-delay fan switch. Include power and control connections in an integral junction box. 2.1.1.6 Efficiency
Minimum steady state efficiencies shall be 78 percent at maximum rated capacity and 75 percent at minimum rated capacity that is provided and allowed by the controls. [2.1.1.7 Accessories
Provide [propane-gas conversion kit] [automatic electric pilot recognition kit]. ]2.1.2 Oil-Fired Unit Heater
UL 731 and UL labeled. 2.1.2.1 Casing
Minimum [22] [_____] gage [aluminum] [or] [[enamel] [or] [vinyl] coated steel]. Provide removable access door. 2.1.2.2 Heat Exchanger
Minimum 16 gage primary combustion chamber constructed of [perlite-clad steel] [, aluminum-clad steel] [, or] [400 series stainless steel]; minimum 14 gage secondary heating section composed of aluminized, mild, or hot-rolled steel. Provide a flame observation port on the burner side of the heater. 2.1.2.3 Burner
Provide pressure oil-atomizing burner with mechanically forced draft, suitable for fuel oil No. 2. Provide two-stage oil pump. Equip burner motor with a combustion air damper. 2.1.2.4 Controls
Include fan and limit switch, low voltage (24-volt) transformer, electronic flame safeguard with flame safety relay, and electric spark ignition.
SECTION 23 82 00.00 20
Page 3
123044
2.1.2.5
Accessories
Provide [power exhauster,] oil filter, oil pressure regulator, and barometric damper. 2.1.2.6 Efficiency
Minimum steady state efficiencies shall be 81 percent at maximum rated capacity and 78 percent at minimum rated capacity that is provided and allowed by the controls. 2.1.3 [Steam] [or] [Hot-Water] Unit Heater
ASHRAE 33 tested for heating coils; UL listed for motor and controls. 2.1.3.1 Casing
Minimum [20] [_____] gage [steel] [or] [aluminum] with removable access panels or means to remove, service, and maintain major components. 2.1.3.2 Coil
Fin-and-tube coil constructed of [copper,] [red brass,] [90-10 copper nickel,] [or ] [steel] tubes and [copper] [or] [aluminum] fins. Use maximum design pressure of [steam at [_____] pounds per square inch gage (psig)] [and] [hot water at [_____] psig and [_____] degrees F]. 2.1.3.3 Controls
[Automatic controls of [modulating] [on-off-auto] [or] [combination of modulating and on-off-auto] system] [As indicated]. [Provide a three-position selector switch.] 2.1.1 Electric Unit Heater
UL listed; wattage, voltage, phase, and number of steps as indicated. Provide control-circuit terminals and single source of power supply. Heater 5 Kw and larger shall be three-phase, with load balanced on each of the three phases. Limit leaving air temperature below 140 degrees F at 60 degrees F entering air. 2.1.1.1 Casing
Minimum [21] [_____] gage steel. 2.1.1.2 Heating Element
Nickel-chromium heating wire element, free from expansion noise and 60 Hz hum. Embed element in magnesium-oxide insulating refractory. Seal element in high-mass steel or corrosion-resisting metallic sheath with fins. Enclose element ends in terminal box. Space fins at maximum six fins per inch. Limit fin surface temperature 550 degrees Fat any point during normal operation. 2.1.1.3 Controls
Include limit controls for thermal overheat protection of heaters. For remote thermostatic operation, provide contactor rated for 100,000 duty cycles. [Provide a control transformer to supply 120-volt thermostat SECTION 23 82 00.00 20 Page 4
123044
control circuit for each heater.] 2.1.1.4 Wiring
Provide room thermostat for pilot duty.
Completely factory-prewired to terminal strips, ready to receive branch circuit and control connections for 140 degrees F [copper] [or] [aluminum] wiring. [2.1.1.5 Accessories
Provide fan switching devices to independently operate fan motor for summer ventilation and winter heat recovery. ]2.2 INFRARED HEATERS
[Reflector-beam spread] [and] operating conditions as indicated. Provide pre-wired control boxes, thermostats, and reflector [and duct] hangers. 2.2.1 [a. Sheet Metal Aluminum-Clad Steel: ASTM A463/A463M, nominal thickness of minimum 16 gage for radiant tubing between burners and vacuum pump or vent.] Aluminum: ASTM B209, manufacturer's standard thickness.] ASTM A167, nominal thickness of not less than 20
[b. [c.
Stainless Steel: gage.]
[d.
[Ceramic-Coated] [Enamel-Coated] Steel: ASTM A1011/A1011M hot rolled orASTM A109/A109M cold rolled, low-carbon steel. Provide coating able to withstand infrared heater operating temperatures.] Unvented Gas Infrared Heater
2.2.2
ANSI Z83.19/CSA 2.35 and AGA approved. 2.2.2.1 Heating Element
Perforated ceramic capable of withstanding thermal shock in [3] [_____] minutes from 2000 to 32 degrees F without fatigue and of minimum 1600 degrees F operating temperature. When re-radiating screens are used to obtain operating temperature, provide [stainless-steel] [or] [chromized-steel] matching screen. 2.2.2.2 Reflector
[Polished [aluminum] [stainless steel]] [or] [approved high infrared reflector materials]. Provide reflector supports of manufacturer's standard. 2.2.2.3 Controls
Provide either an intermittent pilot ignition system or a solid-state direct ignition system. Provide automatic gas safety valve capable of withstanding a 10 percent voltage fluctuation. 2.2.2.4 Ventilation
Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS. SECTION 23 82 00.00 20 Page 5
123044
2.2.3 Vented Gas Infrared Heater ANSI Z83.19/CSA 2.35 with AGA label, [single-burner power vented] [single-burner vacuum vented] [or] [multiple-burner vacuum vented]. 2.2.3.1 Vent
NFPA 54 and NFPA 211, [Type 316 stainless steel] [or] [high-temperature corrosion-resistant plastic rated for minimum 400 degrees F]. Vent flue gas to outdoors by induced draft. 2.2.3.2 Reflector
[Polished [aluminum] [stainless steel]] [or] [approved high infrared reflector materials]. Provide manufacturer's standard reflector supports. 2.2.3.3 Heat Exchanger and Combustion Chamber
Construct heat exchanger and combustion chamber of [aluminum-clad steel] [ceramic-coated steel] [or] stainless steel. 2.2.3.4 Controls
Incorporate either an intermittent pilot ignition system or a solid-state direct ignition system. Provide safety air-flow switch for each burner. 2.2.3.5 Fan or Vacuum Pump
Heater manufacturer's standard. 2.2.3.6 Performance
Provide sufficient radiant heating surface to attain a minimum steady-state thermal efficiency of [80] [85] percent and a maximum heat release of [2,750] [2,900] [2,100] Btu per square foot. 2.2.4 Electric Infrared Heater
Self-contained, factory assembled, and UL listed and including the heating element, reflector, heater housing, mounting brackets, element holders, wire guards, and high-temperature internal wiring. 2.2.4.1 Heating Element
Minimum 3/8 inch diameter quartz tube or metal sheath with coiled resistor wire. Element operating temperature range shall be 1200 to 1800 degrees F. 2.2.4.2 Heater Housing
[Weatherproof] [aluminum-clad steel] [stainless-steel] [aluminum] [or] [low-carbon steel] construction. Provide a baked enamel finish over a corrosion-resistant primer. Provide a chrome-plated or stainless-steel wire guard to prevent heating elements from accidental damage. Furnish swivel brackets to position heater in any horizontal angle. 2.2.4.3 Reflector
Polished [aluminum] [or] [stainless steel].
SECTION 23 82 00.00 20
Page 6
123044
2.2.4.4
Wiring
Fully enclosed internal wiring. Provide minimum 6 inchslack fixture (heater) wire for connection to branch circuit wiring. [2.2.4.5 Accessories
Provide electric-clock controller with self-starting synchronous motors and snap acting switch, rated for 125 percent of the load which it controls. Provide a 30-second time cycle with an infinitely adjustable "on-off" period each cycle. Equip controller with external indicating knob for manual adjustment from zero to 100 percent. If surface mounted, furnish steel enclosure with a baked enamel finish over a corrosion-resistant primer. If flush mounted, furnish galvanized steel enclosure with knockouts for conduit in bottom and sides. Provide a connection wiring diagram on the inside cover of the enclosure. Where loads exceed the maximum available rating of controller, provide high duty-cycle contactors serving as pilot devices. ]2.2 FAN
Provide [steel] [or] [aluminum] fans with ball or roller bearings for motors over 1/8 horsepower (hp) and sleeve bearings for motors 1/8 hp and under. Provide sleeve bearings with oil reservoir, if not permanently lubricated. 2.3 MOTOR AND STARTER
NEMA MG 1, and NEMA ICS 2, and NEMA ICS 6, respectively. [Provide explosion-proof motors and motor starters where indicated.] Provide continuous-duty motor with built-in automatic reset thermal overload protection. For motor 1/2 hp and larger, use three-phase. Provide single-phase motor of permanent split capacitor or capacitor start. Limit motor speed at 1800 r/min. Wire motor to heater power supply source. 2.5 [NOISE, VIBRATION AND SEISMIC CONTROLS
Section 22 05 48.00 20 MECHANICAL SOUND VIBRATION AND SEISMIC CONTROL.] [2.6 GAS PIPING SYSTEM AND FLUE VENT
Comply with Section 23 11 25 FACILITY GAS PIPING, Section 33 51 15 NATURAL-GAS / LIQUID PETROLEUM DISTRIBUTION, for gas valves and piping. Use UL 441 flue vents [and] [gas-vent roof jacks], of [galvanized steel] [aluminum] [or] [stainless steel]. ][2.7 FUEL OIL [TANK] AND PIPING SYSTEM
Section 33 52 10 SERVICE PIPING, FUEL SYSTEMS. ][2.8 HOT WATER PIPING SYSTEM
Section 23 21 13.00 20 LOW TEMPERATURE WATER [LTW] HEATING SYSTEMS. ][2.9 STEAM AND CONDENSATE PIPING SYSTEM
Section 23 22 26.00 20 STEAM SYSTEM AND TERMINAL UNITS.
SECTION 23 82 00.00 20
Page 7
123044
]2.4
SOURCE QUALITY CONTROL
Special protection is not required for equipment that has a zinc coating conforming to \&[ASTM A123/A123M] [ASTM A653/A653M]&\. Otherwise, protect affected equipment items by manufacturers' corrosion-inhibiting coating or paint system that has proved capable of withstanding salt-spray test in accordance with ASTM B117. Test indoor and outdoor equipment for 125 hours; test outdoor equipment used in a marine atmosphere for 500 hours. For each specimen, perform a scratch test as defined in ASTM D 1654. PART 3 3.1 EXECUTION INSTALLATION
Install equipment where indicated and as recommended by manufacturer's recommendations, NFPA 54, NFPA 90A, NFPA 90B, NFPA 91 and NFPA 211. 3.1.1 Suspensions of Equipment
Provide equipment supports including beam clamps, turnbuckles and twist links or weld-wire chains, wire ropes with rope clips and rope thimbles, threaded-eye rod hangers with lock nuts and heat-duct hangers, threaded-eye bolts with expansion screws, brackets, platform and mounting frame, and vibration isolators. Locate equipment in such a manner that working space is available for servicing, such as vacuum pump and burner removal, access to automatic controls, and lubrication. Provide electrical isolation of dissimilar metals. Clean interior of casings or cabinets before and after completion of installation. 3.1.2 Vents
NFPA 54 and NFPA 211. Provide vents with weatherproofing flashings in accordance with Section 07 60 00 FLASHING AND SHEET METAL. 3.1.3 Electrical Work
NFPA 70 and Division 16, "Electrical Work." When replacing original control wires, provide No. 16 AWG with minimum 105 degrees C insulation. 3.2 FIELD QUALITY CONTROL
Administer, schedule, and conduct specified tests. Furnish personnel, instruments and equipment for such tests. Correct defects and repeat the respective inspections and tests. Conduct inspections and testing in the presence of the Contracting Officer. 3.2.1 Test Instruments and Apparatus
Provide instruments and apparatus currently certified as being accurate to within one percent of their full scale. Use gages with a maximum scale between 1 1/2 and 2 times test pressure. 3.2.2 Field Inspection
Prior to initial operation, inspect equipment installation to ensure that indicated and specified requirements have been met.
SECTION 23 82 00.00 20
Page 8
123044
3.2.3 3.2.3.1
Field Tests Fuel Piping Pressure Tests
[Pneumatically test gas piping at 1 1/2 times operating pressure and check for leakage with soap solution.] [Hydrostatically test fuel oil piping at 1 1/2 times maximum working pressure.] 3.2.3.2 Fire Tests for Nonelectrical Heating Equipment
Test combustion controls and equipment with specified fuel at 100 percent full rated load. During tests, verify proper operation of controls. Adjust burners for maximum efficiency using Orsat or similar apparatus. Maintain firing for at least four hours [, and where high-low-off combustion controls are provided, operate the heating equipment for one hour at low fire and 3 hours at high fire]. For acceptable combustion efficiency, allow maximum 4.5 percent carbon dioxide in flue gases. 3.2.3.1 Insulation-Resistance Tests for Electrical Equipment
At the completion of wiring, test 600 volt wiring to verify that no short circuits exist before or after the attachment of electrical heating equipment to the power source. Make tests with an instrument which applies a voltage of approximately 500 volts for a direct reading of insulation resistance. 3.2.3.2 Operational Tests
After completing fire tests and insulation-resistance tests, operate equipment continuously under varying load conditions to verify functioning of combustion controls, electrical controls, flame safeguard controls, safety interlocks, and specified operating sequence. Run each test for a minimum period of one hour. -- End of Section --
SECTION 23 82 00.00 20
Page 9

PK3 Mech Specs

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

PK3 Mech Specs

Caricato da

Copyright:

Formati disponibili

P1268 Camp Geiger GWOT SOI

AHRI 430 AHRI 440 AHRI 880 AHRI 885

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

ASTM D 3359 ASTM D 520 ASTM E 2016

P1268 Camp Geiger GWOT SOI

UL Bld Mat Dir UL Electrical Constructn

UL Fire Resistance 1.2 SYSTEM DESCRIPTION

P1268 Camp Geiger GWOT SOI

Lettering 1/2 inch 3/4 inch 1-1/4 inch

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

ASTM B 152/B 152M, light cold rolled temper.

P1268 Camp Geiger GWOT SOI

2.10.1.7 ASTM A167 2.9.2

Corrosion Resisting (Stainless) Steel Sheets

Duct Access Doors

P1268 Camp Geiger GWOT SOI

Duct Height (1)

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

Automatic Balancing Dampers

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

Provide adjustable [one-way,] [two-way,] [three-way,][ or ][four-way] air SECTION 23 00 00 Page 20

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

Panel Type Power Wall Ventilators

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

coils with drain pans. 2.11.2.3 Steam Heating Coils

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

Provide the following: SECTION 23 00 00 Page 32

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

Constant Volume, Single Duct Terminal Units

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

P1268 Camp Geiger GWOT SOI

ENERGY RECOVERY DEVICES Rotary Wheel

P1268 Camp Geiger GWOT SOI

connectors. 2.13.1 Desiccant Wheel